ATSG AXOD, AXODE, AX4S Update Handbook

Page 1

INDEX

AXOD/AXODE (AX4S)

UPDAT E H A N D B O O K

HYDRAULIC SYSTEM CHANGES .................................................................................................................. 4

SPACER PLATE IDENTIFICATION ................................................................................................................. 9

PUMP AND VLAVE BODY GASKET IDENTIFICATION ............................................................................. 14

VALVE BODY CHECKBALL LOCATIONS ..................................................................................................... 21

OIL PUMP CHECKBALL LOCATIONS .......................................................................................................... 22

VALVE BODY VALVE LOCATIONS AND IDENTIFICATION ..................................................................... 26

PREMATURE PLANETARY FAILURE ............................................................................................................ 34

INTERMEDIATE CLUTCH PACK CHANGES ............................................................................................... 40

NEW STEEL FORWARD CLUTCH PISTON .................................................................................................. 48

HARSH COASTDOWN SHIFT .......................................................................................................................... 49

SPROCKET RATIO IDENTIFICATION (ALL) ............................................................................................... 51

NEW DESIGN OIL PUMP BEARING WITH INTEGRAL SEAL ................................................................. 56

ACCUMULATOR SPRING IDENTIFICATION (ALL) .................................................................................. 58

LOW SPRAG FREEWHEEL DIRECTION ..................................................................................................... 62

FORWARD CLUTCH WAVE PLATE CHANGE ............................................................................................. 64

FORWARD CLUTCH PACK AND LOW SPRAG OUTER RACE CHANGE ............................................. 68

NEW DESIGN INPUT PLANETARY AND SUN SHELL ............................................................................... 72

NO MOVEMENT OR NO TCC .......................................................................................................................... 75

OIL PUMP CHECKBALL LOCATION CHANGES ........................................................................................ 76

TORQUE CONVERTER AND TURBINE SHAFT SPLINE CHANGES ....................................................... 79

VALVE BODY VALVE LOCATIONS AND IDENTIFICATION ..................................................................... 80

VALVE BODY AND OIL PUMP SPACER PLATE IDENTIFICATION ........................................................ 88

OIL PUMP AND VALVE BODY GASKET IDENTIFICATION ..................................................................... 89

VALVE BODY CHECKBALL LOCATION CHANGES .................................................................................. 92

PREMATURE PLANETARY FAILURE ............................................................................................................ 95

CHAIN COVER AND THRUST WASHER CHANGES ................................................................................... 96

1991-1992 ELECTRICAL DIAGNOSIS ........................................................................................................... 100

NEW DESIGN CHAIN COVER KIT FOR NEW CASE CONNECTOR ..................................................... 103

1993-UP ELECTRICAL DIAGNOSIS .............................................................................................................. 104

NEW DESIGN TCC SOLENOID ...................................................................................................................... 106

VEHICLE SPEED SENSOR CHANGES ......................................................................................................... 108

PRESSURE TAP LOCATIONS ......................................................................................................................... 111

PRESSURE CONTROL PROBLEM DIAGNOSIS ......................................................................................... 112

WINDSTAR AND TAURUS SPACER PLATE IDENTIFICATION .............................................................. 116

LATEST CHAIN COVER AND GASKET CHANGE (NO REVERSE) ........................................................ 119

AXOD AND AXODE

AXODE

AUTOMATIC TRANSMISSION SERVICE GROUP

18639 S.W. 107TH AVENUE

MIAMI, FLORIDA 33157

(305) 670-4161

Page 2

INTRODUCTION

DALE ENGLAND

FIELD SERVICE CONSULTANT

ED KRUSE

TECHNICAL CONSULTANT

WAYNE COLONNA

TECHNICAL SUPERVISOR

PETER LUBAN

TECHNICAL CONSULTANT

JIM DIAL

TECHNICAL CONSULTANT

GREGORY LIPNICK

TECHNICAL CONSULTANT

JERRY GOTT

TECHNICAL CONSULTANT

JON GLATSTEIN

TECHNICAL CONSULTANT

DAVID CHALKER

TECHNICAL CONSULTANT

MIKE SOUZA

TECHNICAL CONSULTANT

ROLAND ALVAREZ

TECHNICAL CONSULTANT

GERALD CAMPBELL

TECHNICAL CONSULTANT

No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without written permission of Automatic Transmission Service Group. This includes all text illustrations, tables and charts.

The information and part numbers contained in this booklet have

been carefully compiled from industry sources known for their

reliability, but ATSG does not guarantee its accuracy.

Updated

October, 2002

Since the introduction of the Ford AXOD transaxle in model year 1986, there have been many major engineering design changes that have affected many of the parts used in the AXOD transaxle. This version of the AXOD "Update Handbook" begins with the 1986 model year and will explain each change, the parts affected by the change, and any parts interchange problems created by the change. This booklet is an updated version of the original.

This updated version of the AXOD "Update Handbook" will also cover the changes that occured in the 1991 model year, when electronic controls were adapted to the AXOD transaxle, making it an AXODE, and now called an AX4S transaxle. We have included the changes on the AX4S transaxle up through and including model year 2002.

We wish to thank Ford Motor Company for the information and illustrations that have made this possible.

AUTOMATIC TRANSMISSION SERVICE GROUP

18639 S.W. 107TH AVENUE

MIAMI, FLORIDA 33157

(305) 670-4161

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Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

FORD AXOD/AXODE

NEW STEEL FORWARD CLUTCH PISTON

CHANGE:

REASON:

PARTS AFFECTED:

INTERCHANGEABILITY:

SERVICE INFORMATION:

The Forward Clutch Piston material has now been changed to "Steel", instead of the previous design aluminum piston, as shown in Figure 39.

To eliminate cracks from occuring in the seal groove and greatly improve durability.

(1)

FORWARD CLUTCH PISTON - Now manufactured out of steel, instead of aluminum, and there are no dimensional changes on the piston (See Figure 39).

Forward Clutch Piston (All Except "SHO" Models) ........................................ F4DZ-7A262-A

Forward Clutch Piston (3.2L "SHO" Models Only) ......................................... F4DZ-7A262-B

Should be used to back service ALL previous models of the AXOD, AXODE and AX4S transaxles. Always upgrade the forward clutch piston with the newest design steel piston using the OEM part numbers listed below.

NEW DESIGN STEEL FORWARD CLUTCH PISTON

Figure 39

Page 49

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Page 51

Page 52

Page 53

Page 54

FORD AXOD AND AXODE (AX4S)

WEAR ON OIL PUMP SHAFT AND BEARING

INTSTALLATION PROCEDURE:

SERVICE INFORMATION:

Oil Pump Drive Shaft ...................................................................................... E6DZ-7B328-A

Pump Bearing With Integral Seal .................................................................... XF2Z-7G184-AA

Pump Body Guide Pin ..................................................................................... T86P-70370-A

Valve Body Guide Pin (.271" Dia. - 2 Required) ............................................ T86P-70100-A

Valve Body Guide Pin (.262" Dia.) ................................................................. T86P-70100-B

Valve Body Guide Pin (.254" Dia.) ................................................................. T86P-70100-C

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

Proper alignment of the oil pump and the valve body are mandatory to prevent premature wear of the oil pump drive shaft and the bearing assembly located in the pump housing. When re-assembling the valve body and oil pump, use the guide pins 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" Diameter) and valve body guide pin T86P-70100-B (.262" Diameter), as shown in Figure 44.

3. Install two "Torx" bolts and torque to 7 to 9 ft.lb.

4. Remove both guide pins.

5. Position the spacer plate on the valve body using a new gasket.

6. Insert two valve body guide pins T86P-70100-A (.271" Diameter, as shown in Figure 45.

7. Install two "Torx" bolts and torque to 7 to 9 ft.lb.

8. Position the oil pump on the valve body using a new gasket.

9. Insert pump body guide pin T86P-70370-A and valve body guide pin T86P-70100-C which is .245" in Diameter.

10. Install two valve body to oil pump retaining bolts and torque to 7 to 9 ft.lb.

Page 55

Page 56

FORD AXOD AND AXODE (AX4S)

EXPLODED VANE RINGS AND PUMP ROTORS

PUMP BEARING CHANGES

CHANGE:

REASON:

INTSTALLATION PROCEDURE:

SERVICE INFORMATION:

Beginning at the start of production for 2001 on all AX4S transaxles, Ford Motor Company introduced a new design pump bearing that includes an integrated seal, as shown in Figure 47. When this new design bearing and seal assembly went into production, it was installed with the

seal on the valve body side of the pump instead of the rotor side.

Greatly reduced pump bearing, pump rotor and vane ring failure, for much improved durability and reliability.

Pump Bearing With Integral Seal .................................................................... XF2Z-7G184-AA

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

Outside Diameter

Is 1.000"

OEM Part Number XF2Z-7G184-AA

"RECOMMENDED ALL MODELS"

AXOD/AXODE (AX4S) - When using the 1st Design bearing with the "Nickel" Seal, install the seal on the valve body side, with the part number facing up, as shown in Figure 48. When using the 2nd Design bearing with the integrated seal, which is recommended, install the bearing assembly with the integrated seal facing the valve body side. The 2nd Design Bearing and Seal assembly will retro-fit back on all AXOD, AXODE and the AX4N up through 1999.

Figure 47

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

Page 57

First Design Bearing

And "Nickel" Seal

"Not Recommended Procedure"

When Using 1st Design

"This Is Recommended Procedure"

When Using 1st Design

AX4S 2nd Design

With Integral Seal

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

Pressure

Is Used

For Lube

Oil Pump

Pressure

Is Used

For Lube

Oil Pump

Pressure

Is Used

For Lube

First Design Bearing

And "Nickel" Seal

Figure 48

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Page 58

FORD AXOD, AXODE, AX4S

ACCUMULATOR SPRING IDENTIFICATION

COMPLAINT:

CAUSE:

CORRECTION:

SERVICE INFORMATION:

Shift quality complaints of various types, mostly harsh shift complaints, after the transmission has been overhauled.

The accumulator springs may have been installed in incorrect positions, or the accumulator piston shafts are scored or worn and are interfering with proper accumulator piston 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.

Ensure that the accumulator springs have been installed in their proper locations. Refer to Figures 49 and 50 for accumulator spring identification and position. We have also provided you with the accumulator spring specifications in Figure 51.

Part numbers for each accumulator spring is provided in the chart in Figure 50.

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

Page 59

ACCUMULATOR SPRINGS

SPRINGS ARE WOUND OPPOSITE OF EACH OTHER TO AVOID COIL BIND

Neutral-Drive

Accumulator

Spring Location

3-4 Accumulator

Spring Location

1-2 Accumulator

Spring Location

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 49

Page 60

Figure 50

AXOD, AXODE, AX4S, NEUTRAL-DRIVE ACCUMULATOR SPRINGS

AXOD, AXODE, AX4S, 1-2 ACCUMULATOR SPRINGS

INNER SPRING

INNER SPRING MIDDLE SPRING

APPLICATION

OUTER SPRING

Color

Blue Orange

Orange

Green

1986-1997 "All Models"

91-94 "All Models"

95-97 "All Models"

98-01 "All Models"

1995 Windstar

1996-01 Windstar

86-90 "3.0 Liter"

88-90 "3.8 Liter"

1998-2001 "All Models"

1995-1997 Windstar Blue

Yellow

Brown

* Purple

Brown

* Pink

Pink

Lt. Brwn

Dk.Brwn

Yellow

None Used

Color

ColorColorColor

Part Number

E6DZ-7G301-A E6DZ-7G300-A

E6DZ-7G267-A

E8DZ-7G267-A

F58Z-7G267-A

E6DZ-7G300-A

F8DZ-7G300-BA

E6DZ-7G301-A

E6DZ-7G326-A

E8DZ-7G326-A

*E8DZ-7G326-A

* Color changed, part number remained the same.

F58Z-7G326-A

E8DZ-7G358-A

*E8DZ-7G358-A

E8DZ-7G358-A

Part Number

Part NumberPart NumberPart Number

1998-2001 "All Models"

AXOD, AXODE, AX4S, 3-4 ACCUMULATOR SPRINGS

INNER SPRING

APPLICATION

OUTER SPRING

Color

Green

Dk. Green

White

Yellow

Plain

1986-1990 3.0 Liter

1991-1997 3.0 Liter

1989-1997 3.8 Liter

1988 3.8L Taurus/Sable

1988 3.8L Lincoln

ColorPart Number

E6DZ-7F288-A

E6DZ-7G266-A

E8DZ-7G266-A

E9DZ-7G266-A

F8DZ-7G266-AA

Part Number

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

Page 61

AXOD, AXODE, AX4S, NEUTRAL-DRIVE ACCUMULATOR SPRING "SPECIFICATIONS"

COLOR OUTSIDE DIAMETER FREE LENGTH WIRE DIAMETER

1.480" (37.61mm)

1.014" (25.75mm)

1.813" (46.05mm)

1.685" (42.82mm) .097" (2.48mm)

.135" (3.44mm)

1.513" (38.43mm) 1.880" (47.46mm)

Blue (Inner)

Orange (Outer)

Green (Outer)

"Ovate" Wire ( )

.898" (22.81mm) 1.439" (36.55mm) .081" (2.06mm)

1.189" (30.21mm) 1.484" (37.69mm) .092" (2.34mm)

1.175" (29.85mm) 1.690" (42.93mm) .098" (2.49mm)

1.181" (30.00mm) 1.785" (45.34mm) .099" (2.52mm)

1.183" (30.05mm) 1.735" (44.07mm) .098" (2.49mm)

AXOD, AXODE, AX4S, 3-4 ACCUMULATOR SPRING "SPECIFICATIONS"

COLOR OUTSIDE DIAMETER FREE LENGTH WIRE DIAMETER

Green (Inner)

Dk. Green (Outer)

Plain (Outer)

White (Outer)

Yellow (Outer)

1.180" (29.99mm) 1.542" (39.19mm)

.902" (22.91mm)

1.507" (38.28mm)

.084" (2.15mm)

1.202" (30.55mm) 1.456" (36.99mm) .106" (2.71mm)

1.216" (30.89mm) 1.443" (36.67mm) .106" (2.71mm)

1.205" (30.61mm) 1.443" (36.67mm) .107" (2.73mm)

1.559" (39.60mm) 1.450" (36.83mm) .126" (3.22mm)

1.587" (40.31mm) 1.408" (35.77mm) .126" (3.22mm)

1.595" (40.52mm) 1.490" (37.85mm) .126" (3.22mm)

AXOD, AXODE, AX4S, 1-2 ACCUMULATOR SPRING "SPECIFICATIONS"

COLOR OUTSIDE DIAMETER FREE LENGTH WIRE DIAMETER

.091" (2.30mm)

Yellow (Inner)

Brown (Inner)

Purple (Inner)

Dk. Brown (Inner)

Brown (Middle)

Pink (Middle)

Yellow (Outer)

Lt. Brown (Outer)

Dk. Brown (Outer)

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 51

Page 62

FORD AXOD, AXODE (AX4S)

LOW SPRAG

HOLD

OVERDRIVE DRUM

FREEWHEEL

LOW SPRAG

OUTER RACE

THE LOW SPRAG OUTER RACE MUST FREEWHEEL COUNTER CLOCKWISE

AND LOCK CLOCKWISE WHEN HOLDING THE OVERDRIVE DRUM

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 52

Page 63

HOLD

INNER RACE

FREEWHEEL

OUTER RACE

FORD AXOD, AXODE (AX4S)

3RD ROLLER CLUTCH

THE 3RD ROLLER CLUTCH OUTER RACE MUST FREEWHEEL

CLOCKWISE AND LOCK COUNTER CLOCKWISE WHEN THE

3RD ROLLER CLUTCH INNER RACE IS HELD

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 53

Page 64

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

FORD AXOD/AXODE

FORWARD CLUTCH WAVE PLATE CHANGE

CHANGE:

REASON:

PARTS AFFECTED:

INTERCHANGEABILITY:

SERVICE INFORMATION:

The Forward Clutch Wave Plate has been changed three times since the transaxle was introduced in model year 1986.

To help improve garage shift engagements and to help improve the 4-2 and 3-2 forced downshifts.

(1)

FORWARD CLUTCH WAVE PLATE: 1ST DESIGN - Has 4 external teeth, an inside diameter of 4.715", material thickness of .062", and

was used from 1986-1988. Refer to Figure 54. 2ND DESIGN - Has 21 external teeth, inside diameter of 4.730", material thickness of .075",

identified with letter "X" stamped on 1 tooth, and was used from 1989-1991. (See Figure 55). 3RD DESIGN - Has 21 external teeth, inside diameter of 4.930", material thickness of .083",

identified with letter "A" stamped on 1 tooth, used in 1992 and later models. (See Figure 56).

The 2nd design forward clutch wave plate will retro-fit back to all previous models and is the recommended wave plate for the AXOD transaxle.

The 3rd design forward clutch wave plate was associated with a change in the entire forward clutch pack and should be used Only with the later design forward clutch pack, which are a larger inside diameter.

Forward Clutch Wave Plate (1st Design) ........................................................... E6DZ-7E085-B

Forward Clutch Wave Plate (1st Design) ........................................................... F0DZ-7E085-A

Forward Clutch Wave Plate (1st Design) ........................................................... F2DZ-7E085-A

Page 65

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 54

4 External Teeth Inside Diameter 4.715" Material Is .062" Thick Part Number E6DZ-7E085-B

FORD AXOD

FORWARD CLUTCH WAVE PLATE

USED 1986-1988

Page 66

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 55

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 CLUTCH WAVE PLATE

USED 1989-1991

Page 67

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 56

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 1 Tooth Part Number F2DZ-7E085-A

Page 68

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

FORD AXOD/AXODE

FORWARD CLUTCH PACK CHANGE

LOW SPRAG OUTER RACE CHANGE

CHANGE:

REASON:

PARTS AFFECTED:

INTERCHANGEABILITY:

SERVICE INFORMATION:

Beginning at start of production for 1992 models, all AXODE transaxles were built with a revised low sprag outer race that required revisions on the forward clutches, both lined and steel plates, a new pressure plate and "Wave" plate.

Improved durability and reliability of the low sprag outer race.

(1)

(2)

(3)

(4)

(5)

LOW SPRAG OUTER RACE - The outer diameter of the race was increased from 4.575" to

4.825", and the width of the race was increased from .600" to .725", as shown in Figure 57. The

Inside Diameter of the sprag race Did Not Change.

FORWARD CLUTCH FRICTION PLATES - Have an increased amount of teeth to 57 Teeth from the previous 52 Teeth, to accommodate the increased diameter of the sprag outer race, as shown in Figure 58.

FORWARD 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 Figure 59.

FORWARD CLUTCH PRESSURE PLATE - Has an increased inside diameter to 4.930" from the previous 4.730", to accommodate the increased diameter of the sprag outer race, as shown in Figure 60.

FORWARD CLUTCH "WAVE" PLATE - Has an increased inside diameter to 4.930" from the previous 4.730", to accommodate the increased diameter of sprag outer race (See Figure 61).

None of the parts listed above are interchangeable with previous design parts. If the sprag outer race is upgraded to the latest design, the forward clutch components must also be upgraded to the latest design level. When all of the above parts are changed as a service package, they will retro-fit back to all previous model AXOD/AXODE transaxles.

Forward Clutch Friction Plates (2nd Design) .................................................... F2DZ-7B164-A

Forward Clutch Steel Plates (2nd Design) ......................................................... F2DZ-7B442-A

Forward Clutch "Wave" Plate (2nd Design) ...................................................... F2DZ-7E085-A

Forward Clutch Pressure Plate (2nd Design) .................................................... F2DZ-7B066-A

Forward Clutch Overhaul Kit (Includes Low Sprag Outer Race) ..................... F2DZ-7D171-A

Page 69

FORD AXOD/AXODE

LOW SPRAG OUTER RACE

USED 1989-1991

FORD AXOD/AXODE

FORWARD FRICTION PLATE

USED 1989-1991

FORD AXODE (AX4S)

LOW SPRAG OUTER RACE

USED 1992 AND LATER

FORD AXODE (AX4S)

FORWARD FRICTION PLATE

USED 1992 AND LATER

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

57 Teeth52 Teeth

4.575" Overall

Outside Diameter

5.750" Overall

Outside Diameter

5.750" Overall

Outside Diameter

Increased

Inside Diameter

4.825" Overall

Outside Diameter

"Step" On Both Sides

"Flat" On Both Sides

Inside Diameter Did Not Change

Inside Diameter

Did Not Change

Figure 58

Figure 57

Page 70

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 60

Figure 59

FORD AXOD/AXODE

FORWARD STEEL PLATE

USED 1989-1991

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

4.920"

Inside Diameter

4.930"

Inside Diameter

4.720"

Inside Diameter

4.730"

Inside Diameter

Page 71

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 61

21 External Teeth Inside Diameter 4.730" Material 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 "WAVE" PLATE

USED 1989-1991

FORD AXODE (AX4S)

FORWARD "WAVE" PLATE

USED 1992 AND LATER

Increased

Inside Diameter

Page 72

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

FORD AXOD/AXODE

NEW DESIGN INPUT PLANETARY CARRIER

AND SUN GEAR AND SHELL ASSEMBLY

CHANGE:

REASON:

PARTS AFFECTED:

INTERCHANGEABILITY:

SERVICE INFORMATION:

Beginning at start of production for 1992 models, all AXODE transaxles were built with a new caged needle bearing added to the shaft on the Input Planetary Carrier, which also required a change on the Sun Gear and Shell assembly.

To better stabilize the sun gear and shell assembly for improved durability and reliability, of center gearbox concerns.

(1)

(2)

INPUT PLANETARY CARRIER - New caged needle Bearing added to the shaft on the Input Planetary Carrier, as shown in Figure 62.

SUN GEAR AND SHELL ASSEMBLY - Single bushing is now located in front of the lube holes in the sun gear, and the area behind is now machined to accommodate the new caged needle bearing, as shown in Figure 63.

When you order an Input Planetary Carrier and/or a Sun Gear and Shell assembly from OEM, they will automatically supercede to the new service package part number F4DZ-7A398-A, which includes both of the new design parts listed above.

The new design parts listed above will back service all previous models, but must be used together

as a set.

The new design parts are not compatable with the previous design parts.

Page 73

NEW DESIGN INPUT PLANETARY CARRIER

Caged Needle Bearing Added

On The Shaft Located Here

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 62

Page 74

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 63

PREVIOUS DESIGN SUN GEAR AND SHELL

NEW DESIGN SUN GEAR AND SHELL

Bushing Placement

New Placement Of Bushing

This Area Now Machined To

Accommodate New Caged Bearing

Page 75

Figure 64

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

FORD AXOD/AXOD-E

NO MOVEMENT OR NO CONVERTER CLUTCH

COMPLAINT:

CAUSE:

CORRECTION:

SERVICE INFORMATION:

OIL PUMP DRIVE SHAFT

B C D E

NOTE: THERE ARE ADJOINING HOLES ON THE OPPOSITE SIDE

OF THE OIL PUMP DRIVE SHAFT THAT ARE NOT ILLUSTRATED.

APPLY AIR PRESSURE INTO HOLE "D" AND ENSURE THAT

AIR PRESSURE ESCAPES THROUGH HOLE "C" ONLY.

APPLY AIR PRESSURE INTO HOLE "A" AND ENSURE THAT

AIR PRESSURE ESCAPES THROUGH HOLES "B"&"E" ONLY.

Before and/or after rebuild, the vehicle exhibits one of the following conditions:

1. "No Movement" in forward or reverse.

2. "No Converter Clutch" apply at any speed.

The cause may be, one of the following:

1. The converter feed passage in the Oil Pump Drive Shaft blocked with debris or was not machined properly to allow converter feed oil to enter the converter.

2. The Oil Pump Drive Shaft leaking or not machined properly, allowing converter feed passage and converter release passage to be connected.

Refer to Figure 64 to check the Oil Pump Drive Shaft, and clean or replace as necessary.

NOTE: We have seen some replacement shafts, both reman and new that were leaking between the converter apply and release passages.

Oil Pump Drive Shaft (AXOD/AXODE) ................................................. E6DZ-7B328-A

Page 76

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

THE REMAINDER OF THIS MANUAL WILL BE

DEDICATED TO THE AXODE TRANSAXLE

OIL PUMP CHECKBALL LOCATION CHANGES

FORD AXODE

"Early" 1991 Only - Uses 5 checkballs in the locations shown in Figure 65. Use chart above to determine Early or Late transaxle by serial number. "Late" 1991 Only - Uses 4 checkballs in the locations shown in Figure 65. Use chart above to determine Early or Late transaxle by serial number. 1992-1998 Only - Uses 4 checkballs but in different locations, as shown in Figure 66. B-13 checkball was eliminated and B-2 checkball was added. 1999-2002 Only - Uses 3 checkballs in the locations shown in Figure 66. B-5 checkball was eliminated.

Up To And Including

Serial Number

Vehicle Line

1991 Taurus/Sable 3.8L 54553

39653

10936

195343

PNA-EA

PNA-EC

PNA-EB

PNA-EE

1991 Continental 3.8L

1991 All Police 3.8L

1991 Taurus/Sable 3.0L

Model Code

Page 77

CHECKBALL LOCATIONS "EARLY" 1991 "ONLY"

CHECKBALL LOCATIONS "LATE" 1991 "ONLY"

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 65

CHECKBALL LOCATIONS "LATE" 1991 "ONLY"

B-5

B-13

B-11

B-10

B-12

B-12 Eliminated

B-5

B-11

B-10

Page 78

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 66

CHECKBALL LOCATIONS 92-98 MODELS "ONLY"

CHECKBALL LOCATIONS 1999 AND LATER "ONLY"

B-5

B-5 Eliminated

B-13 Eliminated

B-11

B-2 Checkball

Added

B-2

B-10

B-12 Still Not Used

B-13 Still Not Used

B-12 Still Not Used

Page 79

Figure 67

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

FORD AXOD/AXOD-E

CONVERTER TURBINE SPLINES CHANGE

FROM 23 TEETH TO 25 TEETH

CHANGE:

REASON:

PARTS AFFECTED:

INTERCHANGEABILITY:

Two "Notches" 180 Degrees

Apart Indicate a 25 Tooth

Turbine Hub

INNER VIEW OF

CONVERTER HUB

OPENING

CONVERTER

STAMP CODE

(23 TEETH)

18 Or 36 19 Or 45

28 Or 42

29 Or 39

30 Or 44

31 Or 41

24 Or 37

25 Or 38

26 Or 43

27 Or 40

CONVERTER STAMP CODE

(25 TEETH)

1994 Models Could Be Either

1993-Back Models: Are 23 Spline From OEM

1995-Up Models: Are 25 Spline From OEM

"Do Not" Use I.D. Stamp Code For

Identification If Converter Has Been

Re-Manufactured

Beginning on December 20, 1993, for the 1994 production schedule, Ford Motor Co. changed the converter turbine splines and the turbine shaft splines to 25 teeth from previous 23 splines.

Improved durability for higher torque applications.

(1)

(2)

TORQUE CONVERTER - Converter turbine splines changed from 23 splines to 25 splines. To identify this change, the converter "Stamp Code" was changed. Refer to the chart found in Figure 67 for identification, if the converter has not been rebuilt.

TURBINE SHAFT - Splines changed from 23 splines to 25 splines. Count the number of splines on turbine shaft for positive identification.

If replacement of either torque converter and/or turbine shaft is necessary, ensure that equal number of splines exist on the mating parts.

CAUTION: It is possible to install a 25 Spline converter onto a 23 Spline turbine shaft. If this occurs, the vehicle will have a "No Movement" condition and after the engine is started will usually twist off the stator shaft (Drive Sprocket Support).

Page 80

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

VALVE BODY BORE NUMBERS

AND VALVE IDENTIFICATION

FORD AXODE

VALVE BODY

FRONT VIEW

VALVE 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 and the function identified, as shown on the following pages. Most of the manuals presently in print are wrong.

USE THIS MANUAL TO PROPERLY ASSEMBLE THE AXODE (AX4S) VALVE BODY

Figure 68

Page 81

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 69

VALVE BODY BORE NUMBERS

AND VALVE IDENTIFICATION

FORD AXODE

Valve Body

Bore Number

Valve Number Description

Pressure Failsafe Valve

Backout Valve (Found In Early 1991 Only)

Backout Valve (Found In Late 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 Clutch Regulator Valve

Shift Solenoid Regulator Valve

2-3 Servo Regulator Valve

Manual Valve

2-3 Shift Valve

1-2 Shift Valve

3-4 Shift Valve

Forward Clutch Control Valve

Pull-In Control Valve

Neutral/Drive Engagement Control Valve

3-2 Control Valve (If Retainer Breaks, 3-Neutral Shift)

Intermediate Clutch Shuttle Valve

Main Regulator Valve (Note Direction Of Spring Seat)

Accumulator Regulator Valve

1-2 Capacity Modulator Valve

Page 82

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 70

Early 1991 Only

1. PRESSURE FAILSAFE VALVE

2. BACKOUT VALVE (EARLY 1991)

3. BACKOUT VALVE (CURRENT)

4. ACCUMULATOR REGULATOR VALVE PLUNGER

5. ACCUMULATOR REGULATOR VALVE

6. 1-2 CAPACITY MODULATOR VALVE

Page 83

Figure 71

AUTOMATIC TRANSMISSION 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. CONVERTER REGULATOR VALVE

13. SOLENOID REGULATOR VALVE

Page 84

Figure 72

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

14. MANUAL VALVE

15. 2-3 SHIFT VALVE

Page 85

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 73

16. 1-2 SHIFT VALVE

17. INTERMEDIATE CLUTCH SHUTTLE VALVE

18. 3-4 SHIFT VALVE

19. FORWARD CLUTCH CONTROL VALVE

Page 86

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 In 1999

And Later

Page 87

Figure 75

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

20. PULL-IN CONTROL VALVE

21. 3-2 CONTROL VALVE

Revised Spring

Retainer Clip

F1DZ-7F194-A

Valve Body Front View

FORD AXODE

3-NEUTRAL KICKDOWN SHIFT

COMPLAINT:

CAUSE:

CORRECTION:

A delayed shift may occur during 3-2 forced downshifts, or "Kickdown", and/or the transaxle will shift to neutral during the 3-2 kickdown.

The cause may be, a broken spring retainer clip between the pull-in control valve spring and the 3-2 control valve spring, as shown in Figure 75.

Replace the spring retainer clip with OEM part number F1DZ-7F194-A, as shown in Figure

75.

Page 88

Figure 76

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

OEM Part Number Code Application

Ford Taurus SHO

Ford Taurus/Sable

Lincoln Continental

Ford Taurus/Sable

Ford Windstar

Ford Windstar (W/VB's XD29-AB/AC/BB)

Ford Taurus/Sable

Model Year Engine

F5DZ-7Z490-B

F5DZ-7Z490-C

F5DZ-7Z490-D

F58Z-7Z490-A

F58Z-7Z490-B

F6DZ-7Z490-FB

F68Z-7Z490-A

F88Z-7Z490-AA

XF2Z-7Z490-AA

YF1Z-7Z490-AA

3.2L

3.0L

3.0L/3.8L

3.0L

3.8L

1994-1995

1996-1998

1996-1997

1994

1995

1998

1999

2000-2002

42(97)*

47(67)*

OEM Part Number Code Application

Lincoln Continental

Ford Windstar

Ford Windstar, Ford Taurus/Sable

Ford Taurus/Sable and Windstar

Model Year Engine

F5DZ-7R167-A

F58Z-7R167-A

X2FZ-7R167-AA

1994 3.8L

3.8L

3.0L

3.0L/3.8L

ALL1994-1995

1996-1998

1999-2002

1995-1998

AX4S BONDED PUMP SPACER PLATES

AX4S BONDED VALVE BODY SPACER PLATES

OEM Part Number F6DZ-7Z490-FB has a "42" code and replaces the "97" code, as the "97" code spacer plate is no longer available.

OEM Part Number F68Z-7Z490-A has a "47" code and replaces the "67" code, as the "67" code spacer plate is no longer available.

AXODE (AX4S)

PUMP AND VALVE BODY SPACER PLATE IDENTIFICATION

CAUTION: Part Numbers may change or supercede without notice.

Page 89

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

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-7G331-A

(Green I.D. Stripe)

AXODE (AX4S) PUMP GASKETS

Page 90

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

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)

SPECIAL NOTE:

Color Of The I.D. Stripe May

Vary From Different Suppliers

AXODE (AX4S) 1991-1998

V.B. GASKETS

Page 91

Figure 79

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service 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 The I.D. Stripe May

Vary From Different Suppliers

AXODE (AX4S) 1999-2002

V.B. GASKETS

Page 92

Figure 80

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

NO. 4 NO. 1 NO. 6

NO. 3

NO. 7NO. 9

Alignment

Dowel

Relief

Valve

Relief

Valve

Filters

NO. 8

AXODE (AX4S) 1991-1992 ONLY

CHECKBALL AND RELIEF VALVE LOCATIONS

Page 93

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 81

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

CHECKBALL AND RELIEF VALVE LOCATIONS

Page 94

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 82

AXODE (AX4S) 1999-2002

CHECKBALL AND RELIEF VALVE LOCATIONS

NO. 4 NO. 1 NO. 6

NO. 3

NO. 9

Alignment

Dowel

Relief

Valve

Relief

Valve

Filters

NO. 8

Page 95

Figure 83

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

PREMATURE PLANETARY FAILURE

ORIGINAL

REAR

LUBE TUBE

DIFF/SPEEDO

LUBE TUBE

AXODE (AX4S)

COMPLAINT:

CAUSE:

CORRECTION:

SERVICE INFORMATION:

Front planetary and gear train failure with no visible root cause.

The cause may be, a limited 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 the volume of lube oil to the front planetary system, as shown in Figure 83. This requires the rear lube tube to "Cross-over" the differential and speedo lube tube, as shown in Figure 83. This change was implemented in mid-year 1992 for all AXODE transaxles.

Crossover Rear Lube Tube ....................................................................... F2DZ-7G084-A

Differential/Speedo Lube Tube ................................................................. F2DZ-7G086-A

Page 96

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

FORD AXODE (AX4S)

CHANGES FOR THE CHAIN COVER AND

NO. 1 AND NO. 3 THRUST WASHERS

CHANGE:

REASON:

PARTS AFFECTED:

INTERCHANGEABILITY:

SERVICE INFORMATION:

(1)

(2)

(3)

Beginning on October 13, 1995, introduced as a running change for 1996 models, the AX4S transaxles were built with new design Number 1 and Number 3 thrust washers (See Figure 84).

To improve the assembly process.

NUMBER 1 THRUST WASHER - New design washer has symetrically located tabs for ease af assembly, as opposed to the previous design with non-symetrically located tabs. Refer to Figure 84 for illustrations of both designs.

NUMBER 3 THRUST WASHER - New design washer is Black plastic with 3 symetrically located tabs, as opposed to previous design bronze washer with tangs on the outside diameter. Refer to Figure 84 for illustrations of both designs.

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 symetrically located tabs, as shown in Figure 86. The previous design Chain Cover will accept only the bronze No. 3 thrust washer with the tangs on the outside diameter, as shown in Figure 85. The new design Chain Cover will accept only the new design No. 1 thrust washer with 3 symetrically located tabs, as shown in Figure 86. The previous design Chain Cover will accept only the previous design No. 1 thrust washer with 3 non-symetrically located tabs, as shown in Figure 85.

If replacement of the number 1 and/or the number 3 thrust washer becomes necessary, inspect the chain cover in the thrust washer tab areas to determine the correct thrust washers required. Refer to Figures 85 and 86.

Number 1 Thrust Washer (Before 10/13/95) .....................................................

Number 3 Thrust Washer (Before 10/13/95) .....................................................

Number 1 Thrust Washer (On or After 10/13/95) ..............................................

Number 3 Thrust Washer (On or After 10/13/95) ..............................................

E6DZ-7G099-A E6DZ-7G096-A F5DZ-7G099-A F5DZ-7G096-A

Page 97

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 84

PREVIOUS DESIGN NEW DESIGN

NUMBER 1 THRUST WASHER

WITH NON-SYMETRICALLY LOCATED TABS

PART NUMBER E6DZ-7G099-A

NUMBER 1 THRUST WASHER

WITH SYMETRICALLY LOCATED TABS

PART NUMBER F5DZ-7G099-A

NUMBER 3 PLASTIC THRUST WASHER

WITH SYMETRICALLY LOCATED TABS

PART NUMBER F5DZ-7G096-A

NUMBER 3 BRONZE THRUST WASHER WITH TANGS ON OUTSIDE DIAMETER

PART NUMBER E6DZ-7G096-A

Page 98

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

Page 99

NO. 1 THRUST WASHER LOCATION

WITH SYMETRICALLY LOCATED

HOLES FOR THRUST WASHER

NO. 3 THRUST WASHER LOCATION

WITH SYMETRICALLY LOCATED

HOLES AND CAST GROOVES

FOR THRUST WASHER RETENTION

CHAIN COVER 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

ARE SYMETRICALLY LOCATED

PART NUMBER F5DZ-7G099-A

NUMBER 3

THRUST WASHER

NUMBER 1

THRUST WASHER

Figure 86

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Page 100

100

Technical Service Information

AUTOMATIC TRANSMISSION SERVICE GROUP

FORD AXOD-E (1991-1992 ONLY)

ELECTRICAL DIAGNOSIS (UPDATED)

EPC SOLENOID:

TRANSAXLE OIL TEMPERATURE SENSOR (TOT):

MODULATED LOCK-UP SOLENOID (MLUS):

LOCK-UP SOLENOID (LUS):

Wires for the Electronic Pressure Control solenoid are fed through pins 1 and 6 of the "Black/Gray" case connector, located on top of the transaxle (See Figure 88). Ohmmeter across terminals 1 and 6 should read

2.5-6.5 Ohms resistance.

Wires for the Modulated Lock-Up Solenoid (MLUS) are fed through pins 4 and 5 of the "Gray" case connector, located on top of the transaxle (See Figure 88). Ohmmeter across terminals 4 and 5 should read

0.75-2.0 Ohms resistance if you have MLUS. The Modulated Lock-Up Solenoid (MLUS) is found on the Lincoln Only for the 1991 model year. Taurus/Sable for 1991 are the regular Lock-Up Solenoid (LUS) that is described below. All models for 1992 model year are MLUS.

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 16-40 Ohms resistance if you have LUS. The Lock-Up Solenoid (LUS) is found on the Taurus/Sable Only for the 1991 model year. Lincoln for 1991 is the Modulated Lock-Up Solenoid (MLUS) that is described above. All models for 1992

model year are MLUS.

CAUTION! POPPED A COMPUTER LATELY? CAUTION!

CAUTION! CAUTION! CAUTION! CAUTION! CAUTION!

TOT 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

267-302131-150

Wires for the Transaxle Oil Temperature (TOT) sensor are fed through pins 2 and 3 of the "Black/Gray" case connector, located on top of the transaxle (See Figure 88). Ohmmeter across terminals 2 and 3 should read the approximate resistance listed in the chart below. Resistance should decrease if transaxle is heated, and should increase if transaxle is allowed to cool. Oil pan that is warm to the touch is about 105°F-158°F.