Ford Festiva. Instruction - part 108

Fig. 24: Measuring Output Shaft Bearing Preload

Courtesy of FORD MOTOR CO.

3. Unthread gauge tool until output shaft bearings are seated and no play exists. Install Torque Adapter (T87C77000-E) over splined end

of output shaft. Using INCH lb. torque wrench, rotate output shaft while unthreading gauge tool. Unthread gauge tool until 4.42-7.97
INCH lbs. (.5-.9 N.m) of turning torque is obtained.

4. Using feeler gauge, measure gap of gauge tool. Select correct thrust shim(s) that match measured gauge tool gap. Shims are available

from in thicknesses of .004" (.10 mm) to .007" (.18 mm) in .02 mm increments. One shim is available in thickness of .019" (.50 mm).

5. Disassemble output bearing and idler support from converter housing. Remove gauge set and spacers. Install selected shim(s) in output

bearing and idler support. DO NOT exceed 7 shims. Remove bearing race from gauge tool and install race in support. Reassemble
converter housing and output bearing and idler support. Install bolts and tighten retaining bolts to specification. Refer to

TORQUE

SPECIFICATIONS

6. Install Torque Adapter (T87C77000-E) over splined end of output shaft. Using INCH lb. torque wrench, rotate output shaft to confirm

correct bearing preload. Turning torque should be .26-7.96 INCH lbs. (.03-.9 N.m). If turning torque is not within specification, repeat
steps 1) through 6).

7. Once correct output shaft bearing preload is obtained, remove output bearing and idler gear support. Replace idler gear shaft seal on

idler gear shaft. Install idler gear into converter housing. Install output gear and bearing support. Ensure alignment groove in idler gear
shaft is aligned with support ridge of output bearing and idler support.

8. Install new idler gear shaft roll pin. Install output gear and bearing support bolts and tighten bolts to specification. See

TORQUE

SPECIFICATIONS

DIFFERENTIAL BEARING PRELOAD ADJUSTMENT

1. Install differential assembly into converter housing. Position differential side bearing race in recessed end of Gauge Tool (T87C-

770002DJ). Place gauge tool on differential. See

Fig. 25

2. Ensure gauge tool is completely threaded together so that no gap is present. Position spacer collars and assemble case halves using

supplied bolts and washers of tool set. See

Fig. 25

. Tighten bolts to 22-34 ft. lbs. (292D46 N.m).

Fig. 25: Measuring Differential Bearing Preload

Courtesy of FORD MOTOR CO.

3. Unthread gauge tool until differential bearings are seated. Install Differential Rotator into differential assembly. Using INCH lb. torque

wrench, rotate differential assembly while unthreading gauge tool. Unthread gauge tool until 4.3 INCH lbs. (.5 N.m) of turning torque is
obtained.

4. Using feeler gauge, measure gap of gauge tool. Select correct thrust shim(s) by adding .006" (.15 mm) to measured gauge tool gap. Shims

are available from in thicknesses of .043" (1.08 mm) to .079" (2.00 mm) in .040 mm increments.

5. Disassemble case halves. Remove gauge set and spacers. Install selected shim(s) in transaxle case. DO NOT exceed 3 shims. Remove

bearing race from gauge tool and install race in transaxle case. Reassemble transaxle case halves. Install bolts and tighten bolts to
specification. See

TORQUE SPECIFICATIONS

6. Install Differential Rotator (T88C-77000-L) into differential assembly. Using INCH lb. torque wrench, rotate differential assembly to

confirm correct bearing preload. Turning torque should be 18-25 INCH lbs. (21.-2.8 N.m). If turning torque is not within specification,
repeat steps 1) through 6).

FINAL REASSEMBLY

1. Install low-reverse brake piston by applying even pressure on perimeter of piston while rotating slowly. Install 20 return springs and

low-reverse brake hub. Using appropriate compressor, compress return spring and install snap ring. See

Fig. 9

2. Install dished plate with small end of dish facing away from piston. Install clutch discs, retainer ring and one-way clutch. Install one-

way clutch machined surface toward retainer ring. Install snap ring.

3. Using a feeler gauge, ensure clearance between one-way clutch and retainer plate is .031-.041" (.80-1.05 mm). If clearance is not within

specification, select correct retainer plate to obtain correct clearance. Retainer plates are available in thicknesses of .063" (1.60 mm)
to .102" (2.60 mm) in .20 mm increments. Apply air pressure to low-reverse oil passage and check for proper clutch operation. See

Fig.

4. Place converter housing on bench with output shaft facing upward. Install needle bearing over output shaft. Install drum hub assembly

onto output shaft spline. Install needle bearing with thrust washer in recess of drum hub. Install rear planetary carrier onto one-way
clutch race. Install snap ring. Install rear planetary assembly into drum hub. Install oil tubes into transaxle case.

5. Install governor into transaxle case. Ensure alignment mark on governor sleeve is aligned with mark on transaxle case. Install governor

cover.Tighten bolts to specification. Refer to

TORQUE SPECIFICATIONS

. Apply appropriate gasket sealant to converter housing

and install transaxle case. Once case halves are secured in place, ensure all parts previously installed rotate without resistance.

6. Lubricate servo piston with ATF. Assembly servo retainer, piston, piston large seal and spring. Insert assembly into transaxle. Using "C"

clamp and socket, compress assembly and install snap ring.

7. Install thrust bearing and thrust washer. Install sun gear shell with sun gear spacer and sun gear. See

Fig. 8

. Install front planetary

carrier with thrust washer onto sun gear. Install thrust washer and thrust bearing onto front of front planetary carrier.

8. Install seal sleeve to center of front planetary carrier. Install front ring gear. Install front ring gear needle bearing with rollers facing

upward. Install thrust washer. Match tangs on thrust washer with mating holes in rear clutch assembly.

9. Install rear clutch assembly. Install needle bearing. Companion thrust washer is fitted to oil pump support later in reassembly procedure.

Install front clutch assembly. Install band, band strut and band adjusting stop. Tighten band adjusting stop until band is secured in
place.

TOTAL END PLAY ADJUSTMENT

1. Remove oil pump cover from oil pump housing. Set oil pump housing aside. Coat pump support thrust washer with petroleum jelly and

install on end of pump support. Ensure washer tangs mate with holes in pump support.

2. Install pump cover in front clutch drum. DO NOT have front drum adjusting thrust shim installed. Place a straightedge across transaxle

NOTE:

Low/reverse snap ring may not have been installed during production. Snap ring is required
during overhaul reassembly.

case over pump cover. Measure clearance between straightedge and pump cover, or between straightedge and transaxle case. See

Fig.

3. If pump cover is below edge of transaxle case, clearance between straightedge and pump cover should not exceed .004" (.10 mm). If

pump cover is above edge of transaxle case, clearance between straightedge and transaxle case should not exceed .006" (.15 mm).

4. If pump cover and/or transaxle case clearance is correct, total clutch assembly end play will be correct. Total clutch assembly end play

should be .010-.020" (.25-.50 mm). If pump cover and/or transaxle case clearance is incorrect, remove pump cover and replace pump
support thrust washer. Thrust washers are available in thicknesses from .047" (1.20 mm) to .087" (2.20 mm) in .20 mm increments.

5. Reassemble oil pump by aligning marks on oil pump gears. Place pump cover on pump housing. Install and tighten bolts to

specification. See

TORQUE SPECIFICATIONS

. Install oil pump shaft in oil pump and check operation by turning shaft by hand.

Gears should move freely without binding.

6. Install front clutch thrust washer over pump support. Install oil pump to transaxle. Install oil pump bolts. Apply sealant on 2 lower

bolts and tighten bolts to specification. Refer to the

TORQUE SPECIFICATIONS

7. Position transaxle with oil pump facing down. Turn sun shell 2 revolutions. Insert screwdriver between tabs of front clutch and sun shell

deep slots. Using a feeler gauge, measure in the shallow slots. See

Fig. 26

8. End play should be .020-.031" (.50-.80 mm). If end play is not within specification, remove oil pump and install correct thrust washer.

Thrust washers are available in thicknesses of .051" (1.30 mm) to .106" (2.70 mm) in .20 mm increments.

9. Tighten band adjusting stop bolt to 106-133 INCH lbs. (12-15 N.m). Loosen bolt 3 turns and then tighten lock nut to 41-59 ft. lbs. (56-

80 N.m). Install valve body steel check ball and spring in case. Install valve body and oil pan. Install turbine and oil pump shafts. Install
speedometer driven gear, oil dipstick and tube.

10. Install the vacuum modulator valve in transaxle. Make sure correct length control rod is installed in the modulator. Refer to

VACUUM

THROTTLE VALVE DIAPHRAGM (MODULATOR) R & I

under ON-VEHICLE SERVICE. Install kickdown solenoid and

park/neutral switch. Install torque converter. With converter properly installed, distance between machined pad on torque converter and
front edge of transaxle housing should be .50" (12.7 mm).

Fig. 26: Measuring Front Drum & Total End Play

Courtesy of FORD MOTOR CO.

Fig. 27: Identifying Needle Bearings & Thrust Washers

Courtesy of FORD MOTOR CO.

NEEDLE BEARING LOCATION

TORQUE SPECIFICATIONS

TRANSAXLE SPECIFICATIONS

Application

Dimension In. (mm)

Needle Bearing

"A"

1.650 (41.90)

"B"

1.846 (46.90)

"C"

2.083 (52.90)

"D"

2.752 (69.90)

Thrust Washer

"A"

1.614 (41.00)

"C"

2.028 (51.50)

"D"

2.756 (70.00)

Application

Ft. Lbs. (N.m)

Axle Nut

116-174 (157-235)

Ball Joint Clamp Bolt

40-50 (54-68)

Idler Gear Lock Nut

94-130 (127-176)

Lug Nut

65-87 (88-118)

Oil Pump-To-Transaxle Case

11-16 (15-22)

Output Bearing/Idler Support Bolt

14-19 (19-26)

Output Shaft/Stator Support Bolt

8-10 (11-14)

Ring Gear

51-62 (69-83)

Torque Converter-To-Drive Plate

25-36 (34-49)

Transaxle Case-To-Converter Housing

22-34 (29-46)

INCH Lbs. (N.m)

Governor Cover Bolts

71-97 (8-11)

Oil Pan Bolts

71-97 (8-11)

Oil Pump Cover

97-124 (11-14)

Upper-To-Lower Valve Body

(1)

Valve Body Bolts

89 (10)

(1)

See

Fig. 19

Application

In. (mm)

Content .. 106 107 108 109 ..