5r55e Assembly

307-01-1 307-01-1Automatic Transmission — 5R44E and 5R55E

ASSEMBLYSpecial Tool(s)Transmission

Installer, TransmissionExtension Housing BushingSpecial Tool(s)307-065 (T77L-7697-F)

Holding Fixture, Transmission307-262 (T93T-77002-AH)

Installer, TransmissionExtension Housing Fluid Seal307-038 (T74P-77052-A)

Adjustment Set, TransmissionBand307-S022 (T71P-77370-A)

Alignment Set, Fluid Pump307-S039 (T74P-77103-X)

Holding Fixture, Transmission307-003 (T57L-500-B)

Alignment Gauge, TransmissionFluid Pump307-431

Aligner, Torque Converter307-331 (T95L-7902-A)

Alignment Gauge, TransmissionFluid Pump307-432

Depth Micrometer303-D026 (D80P-4201-A) orequivalent

Sizer, Piston Seal307-338 (T95L-70010-G)

Alignment Gauge, TR Sensor307-351 (T97L-70010-A)

Shim Selection Gauge307-263 (T93T-77003-AH)

(Continued)

(Continued)

Copyright 2005, Ford Motor CompanyLast updated: 4/18/2006 2006 Ranger, 9/2005


ASSEMBLY (Continued)

Special Tool(s) Special Tool(s)

Compressor, Servo Cover Retainer, Torque Converter307-340 (T95L-77028-A) 307-346 (T97T-7902-A)

Installer, Shift Shaft Fluid Seal Transmission Fluid Pump Seal307-050 (T74P-77498-A) Aligner

307-451/1

Handle, Torque Converter Transmission Fluid Pump Seal307-091 (T81P-7902-C) Sizer

307-451/2

Gauge, TSS Transmission Fluid Pump Seal307-337 (T95L-70010-F) Installer

307-451/3

Aligner, Valve BodyMaterial307-333 (T95L-70010-B)

Item Specification

Multi-Purpose Grease ESB-M1C93-BXG-4 and/or XL-5

MERCON V Automatic MERCON VTransmission FluidXT-5-QMAligner, Valve Body

307-334 (T95L-70010-C)

(Continued)

2006 Ranger, 9/2005



2006 Ranger, 9/2005



2006 Ranger, 9/2005



Item Part Number Description Item Part Number Description

24 7D404 Seal ring — coast clutch and1 7902 Converter assembly —direct clutch piston — inner(contains piston type clutch)(2 required)2 379299-S2 Nut — (attaches converter

25 7A548 Seal ring — coast clutchassembly to flexplate) (4piston — outerrequired)

26 7A262 Piston — coast clutch3 7017 Shaft — input

27 7A480 Spring — coast and direct4 7A248 Seal assembly — converterclutch piston (40 required)hub to converter housing

(also in converter housing 28 7A527 Retainer — coast clutchassembly) piston springs

5 W701451-S301 Screw and seal assembly — 29 E860125-S Retaining ring — 63 mmM10 x 33 (attaches converter (2.52 in) coast and directhousing to case) (8 required) clutch piston

6 7976 Converter housing 30 7B442 Plate — coast (2 required)and direct (4 or 5 required)7 7B472 Plate — fluid pump adapterclutch external steel8 7A136 Converter housing-to-case

31 7B164 Plate — coast (2 required)gasketand direct (4 or 5 required)9 7L323 Seal ring — fluid pumpclutch internal frictionsupport

33 7B066 Plate — coast and direct10 W701431-S300 O-ring — fluid pump shaft toclutch pressure (2 required)inner gear (also in pump

33 E860126-S, Retaining ring — coast andassembly)E860127-S, direct clutch plates (select fit)11 7A103 Support and gear assembly —E860128-S, (2 required)fluid pumpE860129-S

12 W701429- Screw — fluid34 7660 Adapter — coast clutch toS309M pump-to-converter housing (6

front carrierrequired)35 7D063 Gear — sun overdrive13 7D014 Washer — fluid pump input36 7B446 Carrier — planetary gearthrust (select fit) No. 1

front (with trigger wheel)14 7A248 Seal ring — fluid pump37 7L495 Bearing — front planet thrust15 71000 Nut and seal assembly — hex

No. 2intermediate and front band38 7A153 Gear — overdrive ringadjustment/lock (2 required)

39 7A089 Clutch assembly — overdrive16 7C492 Screw — intermediate andone-wayfront band adjuster/lock (2

required) 40 7A658 Shaft assembly — centeroverdrive (includes overdrive17 7D430 Strut — intermediate andone-way clutch 7C109)front band anchor (2 required)

41 W702037-S300 Retaining ring — 110.1 mm18 7A653 Bracket — front band lever(4.4 inch) center shaft in frontto casering gear19 7D433 Shaft — front band actuating

42 W702465-S300 Retaining ring — centerleversupport in case20 7330 Lever — intermediate and

43 7M153 Bearing — center shaft thrustfront band servo (2 required)No. 3, 5 and 9 (3 required)21 7D029 Strut — intermediate and

44 E826160-S76 Nut and cage assembly —front band apply (2 required)(attaches center support to22 7D034 Band assembly —case)intermediate and front (2

45 E804373-S Screw cap (attaches centerrequired)support to case)23 7L669 Drum assembly — front

(Continued)brake and coast clutch(Continued)

2006 Ranger, 9/2005




46 7M101 Sensor — turbine shaft speed 69 E860122-S Retaining ring — 87 mm(TSS) (3.48 inch) forward and

output shaft ring gears to47 W702297-S300 Screw — turbine shaft speedhubs (2 required)sensor

70 7B067 Hub — forward ring gear48 7A130 Support assembly — center71 7D392 Gear — forward ring (7249 7D014 Bearing — intermediate brake

external teeth and 57 internaldrum thrust (select fit) No. 4teeth)

50 7D433 Shaft — intermediate band72 7F374 Bearing — forward planetactuating lever

thrust No. 751 7D044 Drum assembly —

73 7A398 Planet assembly — forwardintermediate brake and direct(6 pinion)clutch

74 E860121-S Retaining ring — 39 mm52 7A548 Seal ring — direct clutch(1.56 inch) input shell to sunpiston outergear assembly (2 required)

53 7A262 Piston — direct clutch75 7D063 Gear assembly — sun

54 7A527 Retainer — direct clutch (forward)piston spring

76 7D064 Shell — input55 7A360 Cylinder assembly — forward

77 7M151 Bearing assembly —clutchlow/reverse planet carrier

56 7A548 Seal ring — forward clutch thrust No. 8piston inner

78 7D006 Planet assembly —57 7A548 Seal ring — forward clutch low/reverse (6 pinion)

piston outer79 7B176 Sleeve — output

58 7A262 Piston assembly — forward80 7A153 Gear — output shaft ringclutch81 E860527-S Retaining ring — 25 x 2 mm59 7A480 Spring — forward clutch

(0.08 inch) output shaft inpiston (15 required)case

60 7A527 Retainer — forward clutch82 7D164 Hub — output shaftpiston spring83 7C498 Drum assembly —61 E860109-S Retaining ring — 34 mm

low/reverse brake (includes(1.36 inch) forward clutchoverrunning clutch)piston and spring in forward

clutch cylinder 84 7D001 Bearing — part of reversedrum62 7B070 Spring — forward clutch

cushion 85 7A089 Clutch assembly — part ofreverse drum63 7B442 Plate — forward clutch

external steel (6 required) 86 7D095 Band — low/reverse

64 7B164 Plate — forward clutch 87 7M150 Bearing race (2 pieces) —internal friction (6 required) output shaft hub thrust No.

10A65 7B066 Plate — forward clutchpressure 88 7M150 Bearing assembly — output

shaft hub thrust No. 10B66 E860115-S Retaining ring — forwardclutch plates in forward 89 7B368 Washer — output shaft thrustclutch cylinder (select fit) No. 11

67 7D234 Bearing — forward ring gear 90 7M167 Gear assembly —hub thrust No. 6A transmission parking

68 7D090 Washer — forward clutch 91 7060 Shaft — output (rear wheelthrust No. 6B drive [RWD])

(Continued) 92 7086 Gasket — extension housing

93 7A441 Pawl — parking(Continued)

2006 Ranger, 9/2005




94 7D070 Spring — parking pawl return 121 7M183 Sensor — intermediate shaftspeed95 7D071 Shaft — parking pawl

122 W703165-S300 Spring — retains 16 pin96 7A039 Extension housing (RWD)connector in case

97 7A034 Bushing — extension housing123 7H103 Sensor — output shaft speed(RWD)

(OSS) 98 7052 Seal assembly — extension

124 390318-S2 Plug — pipe line and EPChousing to slip yoke (RWD)pressure (part of case

99 E804137-S72 Stud — extension housing (1 assembly) (2 required)or 2 required)

125 7034 Vent — (4WD)100 E800152-S72 Screw — extension housing

126 7034 Vent — (RWD)(5 or 6 required)127 W702909-S309 Stud — attaches heat shield101 7060 Shaft — output (four wheel

to casedrive [4WD])128 7F013 Shield — transmission heat102 7A039 Extension housing (4WD)

(4.0L only)103 N605804-S100 Screw — extension housing

129 N620040-S36 Nut — transmission heatto transfer case (5 required)shield

104 W701271-S309 Nut — attaches outer and130 7A160 Tube — lube fluid inlet —inner manual valves to shaft

short (2 required)131 7D273 Connector — fluid tube (2105 7A256 Lever — manual control

required)outer132 7D028 Spring — intermediate servo106 W500015-S309 Screw — digital transmission

and front pistonrange (TR) sensor (2required) 133 7D021 Piston and rod assembly —

intermediate and front servo107 7F293 Sensor — transmission range(TR) 134 7D027 Cover and seal assembly —

intermediate and front servo108 7C493 Shaft — manual valve outerto inner lever 135 7D040 O-ring — servo cover to case

intermediate and front servo109 E840125-S Pin — spring (retains outermanual lever to case) 136 E860343-S Retaining ring — 67 x 1.5

mm (0.06 inch) intermediate110 7B498 Seal — main control lever and front servo

111 7C115 Lever — manual valve inner137 W701099-S430 Screw — attaches separating

112 7A232 Rod — parking pawl plate to main control (3actuating required)

113 7E332 Spring assembly — manual 138 7G383 Solenoid — electronicvalve detent pressure control (EPC)

114 E800185-S72 Screw — attaches detent 139 7G484 Solenoid — transmission shiftspring to main control (SS) (4 required)

115 7Z409 Connector — transmission 140 W702949-S300 O-ring — shift solenoid smallcase (16-pin with wire (13x1.5) (4 required)harness to 6 solenoids)

141 W702951-S300 O-ring — shift solenoid large116 W703015-S300 O-ring — transmission case (15x1.5) (4 required)

(16-pin) connector 142 7G136 Solenoid — torque converter

117 7005 Case assembly (model clutch (TCC) dependent)

143 7L491 Clamp — (SSA and SSC)118 W702297-S300 Screw — M6 x 19 cap solenoids 119 W702981-S300 O-ring — speed sensor 144 7L491 Clamp — TCC/SSD/SSB and

EPC solenoids120 W702297-S300 Screw — OSS sensor (Continued) 145 E800155-S72 Screw — clamp (2 required)

(Continued)

2006 Ranger, 9/2005



2. Inspect the transmission case for the following:Item Part Number Description

146 7A100 Control valve body — main 1 Stripped bolt hole threads.(model dependent) 2 Gasket and mating surfaces for burrs or

147 7Z490 Plate — valve body nicks.separating (bonded)

3 Obstructions to vent and fluid passages.148 E800154-S Screw — M6 x 45 maincontrol valve body (4 • Cracks or warpage.required)

149 E800153-S72 Screw — M6 x 40 maincontrol valve body (16required)

150 E800163-S Screw — M6 x 35 maincontrol valve body (3required)

151 7423 Seal ring — low/reverseservo piston small

152 7423 Seal ring — low/reverseservo piston large

153 7D189 Piston assembly —low/reverse band servo withrod and retainer (select fit)

154 7L173 Gasket — low/reverse servo 3. Inspect the extension housing for cracks, burrscover

or warpage.155 7D036 Cover — low/reverse servo

156 E800156-S Screw — low/reverse servocover (4 required)

157 7A469 O-ring — fluid filterassembly small

158 7A098 Filter — fluid pan (RWD)

159 7A469 O-ring — fluid filterassembly large

160 7L027 Magnet

161 7A191 Gasket — fluid pan

162 W701203- Screw — transmission fluidS309M pan (18 required)

163 7A194 Pan — transmission fluid(RWD)

4. Inspect the case bearing for damage. If damage164 7A098 Filter — transmission fluidto the case bearing is indicated, install a newpan (4WD)case.165 7A194 Pan — transmission fluid

(4WD)

166 E800154-S Screw — fluid filter

A — Coast clutch assembly

B — Direct clutch assembly

C — Forward clutch assembly

All vehicles

1. Thoroughly clean the transmission case andextension housing in solvent and blow dry withcompressed air.

2006 Ranger, 9/2005



5. Install the special tool on the rear of the 8. Using the special tool, install the manualtransmission case. control lever shaft seal.

• Lubricate the manual control lever shaft sealwith petroleum jelly.

6. Attach the fixture arm of the special tool asshown.

9. Assemble the manual valve inner lever andparking lever actuating rod as shown.

7. WARNING: Make sure the lock pin onthe special tool is secure. Failure to followthese instructions may result in personal 10. Install the manual control lever shaft.injury.

Install transmission into the special tool.

• Rotate the transmission so that the fluid panrail is facing up.

2006 Ranger, 9/2005



11. CAUTION: Use care not to damagethe fluid pan rail surface when installing theretaining pin.

NOTE: Align the manual control lever shaftalignment groove with the manual control levershaft spring pin bore in the transmission case.

Install the manual control lever shaft spring pin.

• Tap the manual control lever shaft springpin into the transmission case.

14. CAUTION: The tabs on the No. 11output shaft thrust washer point into thecase. Make sure the thrust washer iscorrectly seated.

Install the No. 11 output shaft thrust washer.

• Coat the output shaft thrust washer withpetroleum jelly.

12. CAUTION: Align the flats on themanual valve inner lever with the flats onthe manual control lever shaft.

Install the manual valve inner lever and parkinglever actuating rod on to the manual controllever shaft.

15. Install the park gear.

13. CAUTION: To avoid damage, do notallow the wrench to strike the manual valveinner lever pin.

Install the manual valve inner lever nut on themanual control lever shaft.

• Tighten to 48 Nm (35 lb-ft).

2006 Ranger, 9/2005



16. Install the low/reverse brake drum. 19. Install the output shaft ring gear and outputshaft hub.• Rotate the low/reverse brake drum clockwise

to install.

20. CAUTION: Always install a newoutput shaft retaining ring.17. If not already installed during subassembly,

install the No. 10B needle bearing onto the Install a new output shaft retaining ring.output shaft ring gear and hub assembly.

• Coat the needle bearing with petroleumjelly.

21. NOTE: Install the output shaft sleeve with thecone facing up.

Install the output shaft sleeve.18. Install the output shaft through the output shaft

park gear.

2006 Ranger, 9/2005



22. Install low/reverse planetary carrier needlebearings.

1 Install the No. 8 low/reverse planetarycarrier needle bearing on the front face ofthe low/reverse planetary.

2 Install the No. 9 low/reverse planetarycarrier needle bearing on the rear face ofthe low/reverse planetary.

• Coat the No. 8 low/reverse planetary carrierneedle bearing and No. 9 low/reverseplanetary carrier needle bearing withpetroleum jelly.

25. CAUTION: Make sure band is restingon the 2 anchor pins in the case.

Install the low/reverse band over thelow/reverse brake drum.

23. CAUTION: Make sure needle bearingsstay in place.

Install the low/reverse planetary assembly withNo. 8 and No. 9 low/reverse planetary carrierneedle bearings into the output shaft ring gear. 26. Temporarily install the low/reverse band servo

piston and rod to hold the low/reverse band inposition.

24. CAUTION: The low/reverse brakedrum must be pulled forward to install thelow/reverse planet retaining ring.

Install the low/reverse retaining ring into thelow/reverse brake drum groove.

2006 Ranger, 9/2005



27. Install the previously assembled forward 30. Calculate the thrust bearing thickness.geartrain assembly. • Extend the micrometer probe until it

contacts the intermediate brake drum thrustbearing surface. Record the reading. This isdimension A.

28. WARNING: Make sure the lock pin onthe special tool is secure. Failure to followthese instructions may result in personalinjury. 31. Place the micrometer on the opposite side of

the special tool and repeat the measurement.Rotate the transmission assembly so that theThis is dimension B.converter housing surface is facing up.

29. Select the No. 4 intermediate brake drum thrustbearing as follows:

1 Install the special tool on the case assemblyshoulder.

2 Set the special tool on top as shown.

32. Add dimension A and B, divide the total of Aand B by 2. Then subtract the special toolthickness 17.78 mm (0.700 inch). Record thisreading as dimension C.

2006 Ranger, 9/2005



33. Place the special tool across the center support.Place the micrometer on the top of the specialtool.

• Extend the micrometer probe until it makescontact with the center support thrustbearing surface. Record this reading asdimension D.

35. Add dimensions D and F, divide the total of Dand F by 2. Subtract the special tool thickness17.78 mm (0.700 inch) dimension E. The resultis dimension G.

34. Place the special tool on the opposite side ofthe special tool.

• Extend the micrometer probe until it makescontact with the center support thrustbearing surface. Record this reading asdimension F.

36. Add dimensions C and G. This total isdimension H. Use the following chart to selectthe correct No. 4 thrust bearing. Reference endplay is 0.20-0.54 mm (0.008-0.021 inch).

Dimension H Service Part Number Bearing Thickness Identification (Notches)

3.01-3.15 mm (0.119-0.124 XW4Z-7D014-CA 2.65-2.80 mm (0.104-0.110 Noneinch) inch)

3.17-3.34 mm (0.125-0.132 XW4Z-7D014-DA 2.80-2.95 mm (0.110-0.116 1inch) inch)

3.36-3.54 mm (0.133-0.140 XW4Z-7D014-EA 3.00-3.15 mm (0.118-0.124 2inch) inch)

3.57-3.71 mm (0.141-0.147 XW4Z-7D014-FA 3.20-3.35 mm (0.126-0.132 3inch) inch)

2006 Ranger, 9/2005



37. Install the intermediate servo actuating lever. 40. NOTE: Make sure that the intermediate applystrut is aligned with the band notch.

Install the intermediate band.

38. NOTE: The intermediate band lever shaft isshorter than the front band lever shaft.

Install the intermediate band actuating lever 41. NOTE: Use the intermediate band adjustingshaft through the intermediate servo actuating screw as a temporary alignment guide.lever. NOTE: The intermediate and front band anchor

struts and band adjustment screws are the same.

Install the intermediate band anchor strut andthe intermediate band adjustment screw.

39. Install the intermediate band apply strut on theintermediate servo actuating lever.

2006 Ranger, 9/2005



42. Install the No. 4 selected intermediate brake 44. CAUTION: Install the center supportdrum thrust washer on the center support. retaining ring with the tapered side facing

up.• Coat the intermediate brake drum thrustwasher with petroleum jelly. CAUTION: Make sure the notch

opening is not obstructed by the centersupport retaining ring.

Install the center support retaining ring.

1 Position the center support retaining ringwith the tapered side facing up.

2 Install the center support retaining ring sothat the notch opening is not obstructed.

43. CAUTION: Do not apply pressure tothe center support while installing. Damageto sealing rings can result.

NOTE: Align the center support screw holewith correct case hole.

Install the center support.

1 Position the center support into theintermediate brake and direct clutch drum.

2 Temporarily insert the input shaft andgently wiggle it until the center support isseated against the case shoulder, thenremove the input shaft.

2006 Ranger, 9/2005



45. Install the center support locknut and cage.

48. CAUTION: Use only the No. 3 centershaft thrust bearing.

46. Loosely install the center support-to-case capNOTE: The No. 3 center shaft thrust bearingscrew.has no notches on the outer race.

Install the No. 3 center shaft thrust bearing.

47. CAUTION: Carefully route the turbineshaft speed (TSS) sensor connector and

49. CAUTION: Do not bend the triggerwiring harness through the opening in thewheel.case. Do not damage the wiring.

Install the overdrive planetary and one-wayNOTE: Route TSS sensor electrical connectorclutch assembly.and wiring through transmission case opening.

Install the TSS sensor.

1 Install the TSS sensor.

2 Install the TSS sensor screw.

X Tighten to 10 Nm (89 lb-in).

2006 Ranger, 9/2005



52. NOTE: Align the clutch plates and front50. CAUTION: The trigger wheeladapter gear.triggering window should pass over the thin

blade of the special tool. If it does not, a new Install the front brake drum and coast clutchoverdrive planetary carrier and trigger wheel drum assembly.must be installed.

Using the special tool, check the TSS sensor airgap.

1 Place the thin blade of the special tool overthe TSS sensor.

2 Rotate the trigger wheel and repeat checksfor all windows.

53. Install the front servo band lever and front bandlever-to-case bracket into the transmission case.

51. CAUTION: The trigger wheeltriggering window should not pass over thethick blade of the special tool. If it does, anew overdrive planetary carrier and triggerwheel must be installed.

Using the special tool, check the TSS sensor airgap.

1 Place the thick blade of the special tool 54. NOTE: The front band lever shaft is longerover the TSS sensor. than the intermediate band actuating lever shaft.

2 Rotate the trigger wheel and repeat checks Install the front band actuating lever shaftfor all windows. through the front servo band lever.

2006 Ranger, 9/2005



55. Install the front band apply strut. 58. Install the front band adjusting screw.

56. NOTE: If the front band is reused, it must be 59. CAUTION: Make sure that the pumpinstalled in its original position. body is seated against the thrust washer and

the front brake and coast clutch drum. TheInstall the front band over the front brake andpump body must be below the level of thecoast clutch drum.case gasket surface.

CAUTION: The tabs on the washer gointo the pump face.

Carry out the front end play check procedure asfollows:

• Coat the No. 1 fluid pump inlet thrustwasher with petroleum jelly.

• Install the No. 1 fluid pump inlet thrustwasher on the rear of the fluid pump andplace the pump into position in the case.

57. NOTE: Use the band adjustment screw as atemporary alignment guide.

Install the front band anchor strut.

2006 Ranger, 9/2005



60. CAUTION: The special tool must rest 61. CAUTION: If the average front endon the gasket surface. clearance is below the specification, choose a

thinner washer. If the average is above theMeasure the front end play clearance.specification, choose a thicker washer.

1 Place the special tool across the case.NOTE: The front end play specification is

2 Insert the special tool and extend the 0.18-0.70 mm (0.007-0.028 inch).micrometer probe until it contacts the fluid

Use dimension C and the chart below to selectpump face.the correct thickness fluid pump inlet thrust

• Read the measurement and subtract the washer (No. 1).special tool thickness 17.78 mm (0.70 inch).This is dimension A. Front End Play Selective Thrust Washer No. 1

• Repeat the measurement at the opposite side Front End Play C 0.18 - 0.70 mm (0.007 - 0.028of the transmission case. This is dimension inch) Without GasketB. Selective Pump Support Thrust Washer

• Add dimensions A and B together and Part Number Thickness Colordivide by 2. This is front end clearance

F7TZ-7D014-VA 1.35 - 1.40 mm Bluedimension C. (0.035 - 0.055

inch)

F7TZ-7D014-TA 1.55 - 1.60 mm White(0.061 - 0.063

inch)

F7TZ-7D014-MA 1.75 - 1.80 mm Green(0.069 - 0.071

inch)

F7TZ-7D014-NA 1.85 - 1.90 mm Red(0.073 - 0.075

inch)

F7TZ-7D014-PA 1.95 - 2.00 mm Beige(0.077 - 0.079

inch)

F7TZ-7D014-RA 2.05 - 2.10 mm Black(0.081 - 0.083

inch)

F7TZ-7D014-SA 2.15 - 2.20 mm Yellow(0.085 - 0.087

inch)

2006 Ranger, 9/2005



62. CAUTION: Make sure that the pumpbody is seated against the thrust washer andthe front brake and coast clutch drum. Thepump body must be below the level of thecase gasket surface.

CAUTION: The tabs on the washer gointo the pump face.

Remove the pump and install the No. 1 thrustwasher onto the pump. After installing selectedfront pump thrust washer No. 1, repeat the frontend play check. Make sure the end play iscorrect, then remove the pump for assembly.

65. CAUTION: The chamber on the insideedge of the small gear must be up when inthe pump housing gear pocket. The dimpleon the larger gear must be down when in thepump housing gear pocket.

Install the pump gears into the fluid pumphousing. Apply multi-purpose grease to thepump gear to prevent scoring at start-up.

63. Install a new O-ring seal in the fluid pumpdrive gear.

66. CAUTION: Make sure the holes in theplate line up with the holes in the pump.

Install the fluid pump adapter plate.

64. CAUTION: Lubricate the special toolwith multi-purpose grease.

Install the fluid pump drive gear on the specialtool to seat the O-ring seal. Remove the tool.

2006 Ranger, 9/2005



67. CAUTION: Do not allow the pumpgears to come out of the pump housingpocket.

NOTE: The notch on the outside of the adapterplate will be at the 9 o’clock position relativeto the converter housing.

Install the fluid pump on the converter housing.

• Hold the fluid pump adapter plate againstthe pump housing. Turn the pump andadapter plate over and place on theconverter housing.

70. Thread the gauge into the special tool and slidethe tool over the fluid pump until it bottoms outin the fluid pump gear pocket.

68. Loosely install the fluid pump screws.

71. Tighten the fluid pump screws in a star patternand remove the pump alignment handle.


69. CAUTION: The special tools must beused to correctly align the fluid pump to thefluid adapter plate. This will prevent sealleakage, gear noise, broken gears andbushing failure.

Align the fluid pump to the fluid pump adapterplate and select the gauge from the special toolthat is the snuggest fit when placed over thefluid pump.

2006 Ranger, 9/2005



72. Install a new fluid pump seal ring.

• Coat the fluid pump seal ring withpetroleum jelly.

75. CAUTION: Verify correct sealinstallation. Make sure seal grooves are cleanand free of burrs.

Verify that the seal is installed correctly.73. NOTE: Make sure the fluid pump seal ring is

installed on the housing and pump assembly.

Install a new fluid pump gasket.

• Hold the fluid pump gasket in place withpetroleum jelly.

76. CAUTION: Failure to correctly sizethe seal will damage the seal when the torqueconverter is installed.

Using the special tool, size the seal to thecorrect size. Leave the special tool on the seal

74. CAUTION: Be careful not to for 2 minutes to obtain the correct seal size.overstretch the seal ring past the seal ringgroove or damage to the seal will occur.

Using the special tools, install the fluid pumpseal ring.

2006 Ranger, 9/2005



77. Install the selected No. 1 fluid pump thrust 80. CAUTION: Make sure that the No. 1washer. fluid pump inlet thrust washer selective

thrust washer, fluid pump gasket and the• Coat the fluid pump thrust washer withfluid pump-to-case O-ring seal remain in thepetroleum jelly.correct position throughout this step.

Install the fluid pump and converter housingonto the case.

78. Install the special tools into the transmissioncase.

81. NOTE: Lubricate the O-ring seals on theconverter housing screws.

Remove the special tools. Install the newconverter housing-to-case screws. Tighten thescrews in a star pattern.


79. CAUTION: The splines on the ends ofthe input shaft are not the same length. Theshorter splines go into the assembly.

Install the input shaft.

2006 Ranger, 9/2005



82. Remove the input shaft. 85. CAUTION: Do not damage the frontservo-to-case O-ring seal during installation.

CAUTION: Do not press the frontservo cover and O-ring seal past the reliefhole in the case or O-ring seal damage canoccur.

Using the special tool, install the front servoassembly into the case and install the frontservo cover retaining ring.

83. WARNING: Make sure the lock pin onthe special tool is secure. Failure to followthese instructions may result in personalinjury.

Rotate the transmission assembly so the fluidpan rails are facing up.

84. Assemble the front servo assembly.

1 Install the front servo cover O-ring seal on 86. Assemble the intermediate servo assembly.the front servo cover. Coat the front servo

1 Install the intermediate servo cover O-ringcover O-ring seal with petroleum jelly.seal on the intermediate servo cover. Coat

2 Install the front servo piston into the front the intermediate servo cover O-ring sealservo cover. with petroleum jelly.

3 Install the front servo piston spring on the 2 Install the intermediate servo piston into thefront servo piston. intermediate servo cover.

3 Install the intermediate servo piston springon the intermediate servo piston.

2006 Ranger, 9/2005



87. CAUTION: Do not damage servo 89. CAUTION: The front servo must becover-to-case O-ring seal during installation. installed prior to band adjustment.

NOTE: The wrench will click at the specifiedCAUTION: Do not press thetorque.intermediate servo cover and O-ring seal

past the relief hole in the case or O-ring seal Using the special tool, tighten the front banddamage can occur. adjustment screw.

Using the special tool, install the intermediate • Tighten to 14 Nm (10 lb-ft).servo assembly into the case and install the • Then back off the front band adjustmentintermediate servo cover retaining ring. screw exactly 2 turns and hold that position.

88. CAUTION: Do not allow front band 90. Tighten the front band locknut.adjustment screw to back out. The band 1 Hold the front band adjustment screwstrut can fall out of position. stationary.

CAUTION: Install, but do not tighten, 2 Tighten the front band locknut.a new locknut on the band adjustment screw.

X Tighten to 61 Nm (45 lb-ft).Apply petroleum jelly to the locknut seal.

Install a new locknut on the band adjustmentscrew.

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93. Tighten the intermediate band locknut.91. CAUTION: Do not allow theintermediate band adjusting screw to back 1 Hold the intermediate band adjustmentout. The band strut could fall out of position. screw stationary.

2 Tighten the intermediate band locknut.CAUTION: Install, but do not tighten,a new locknut on the band adjustment screw. X Tighten to 61 Nm (45 lb-ft).Apply petroleum jelly to the locknut seal.

Install a new nut on the band adjustment screw.

94. CAUTION: Install new O-ring seals onthe 16-pin electrical connector. Coat theO-ring seals with petroleum jelly.92. CAUTION: The intermediate servo

must be installed prior to band adjustment. NOTE: Make sure that the tab is in the lockposition. NOTE: The wrench will click at the specified

torque. Position the transmission case 16-pin electricalconnector into the case bore.Using the special tool, tighten the intermediate

band adjusting screw. • Press the transmission case 16-pin electricalconnector through the case until a click is• Tighten to 14 Nm (10 lb-ft).heard.• Then back off the intermediate band

adjusting screw exactly 2 turns and hold thatposition.

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95. CAUTION: Do not overstretch theretaining spring.

Install the 16-pin electrical connector retainingspring.

97. Tighten the center support screw.


98. Install the special tools into the transmissioncase.

96. CAUTION: Align the slot on the TSSsensor electrical connector with the slot inthe 16-pin electrical connector.

Install the TSS sensor electrical connector intothe transmission case 16-pin electricalconnector.

1 Connect the TSS sensor electrical connector.

2 Insert the TSS sensor electrical connectorwires into the retaining slot in the 16-pinelectrical connector.

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99. CAUTION: Make sure main controlvalve body gasket is aligned.

CAUTION: Make sure that the manualvalve is correctly aligned with the manualvalve inner pin when the main control valvebody is installed.

Position the main control valve body into thetransmission case.

102. NOTE: The main control valve body screwwill be tightened in later steps.

Loosely install the M6 x 30 mm screw.

100. NOTE: The screws will be tightened in latersteps.

Loosely install the 4 M6 x 45 mm screws.

103. Remove the special tools.

101. NOTE: The main control valve body screwswill be tightened in later steps.

Loosely install the 2 M6 x 35 mm screws.

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104. NOTE: The main control valve body screws 105. Tighten the screws in the sequence shown.will be tightened in later steps. • Tighten to 10 Nm (89 lb-in).Loosely install the 16 M6 x 40 mm screws.

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106. Rotate the manual lever into the NEUTRAL 108. Tighten the screws in the sequence shown.position, then install the manual control valve • Tighten to 13 Nm (10 lb-ft).detent lever spring.

1 Position the manual control valve detentlever spring on the main control valve body.

2 Install the screw.

X Tighten to 11 Nm (8 lb-ft).

109. Connect the solenoid electrical connectors.

1 Connect shift solenoids SSA, SSB, SSC andSSD electrical connectors.

2 Connect the torque converter clutch (TCC)solenoid electrical connector.

107. Install the low/reverse band servo cover and 3 Connect the electronic pressure controlreverse servo separator plate cover gasket. (EPC) solenoid electrical connector.

1 Position the low/reverse band servo coverand low/reverse servo separator plate covergasket on the transmission case.

2 Loosely install the screws.

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110. CAUTION: Excessive pressure maybreak the locating pins.

Install the wiring loom protector and guide.

• Align the pins in the holes of the solenoidclamps and gently push down.

113. Position the fluid pan magnet in thetransmission fluid pan.

111. CAUTION: Make sure that both fluidpan filter O-ring seals are correctlyinstalled on the fluid pan filter prior toinstallation.

CAUTION: Lubricate fluid filterO-ring seals with clean automatictransmission fluid or they can be damaged.

Lubricate and install new O-ring seals onto thetransmission fluid filter. 114. Install the transmission fluid pan.

1 Position a new transmission fluid pan gasketon the transmission fluid pan.

2 Install and align the transmission fluid pan.

112. Install the transmission fluid filter.

1 Position the transmission fluid filter on themain control valve body.

2 Install the transmission fluid filter screw.


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115. Loosely install the transmission fluid panscrews.

119. NOTE: Use petroleum jelly to hold the gasketin place.

Install a new extension housing gasket.116. Tighten the transmission fluid pan screws in a

crisscross sequence.


120. NOTE: The guide cup is press-fit into theextension housing and is not servicedseparately.

117. Remove the transmission from the bench and Install the parking pawl assembly.place on a flat surface.

1 Install the parking pawl shaft into theextension housing.

2 Install the parking pawl.

3 Install the parking pawl return spring.

118. Remove the special tools from thetransmission case.

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121. CAUTION: Make sure the parking 123. CAUTION: Tool will bottom whenlever actuating rod is correctly seated into bushing is in the correct position.the case parking rod guide cup. Using the special tool, install the extensionInstall the extension housing. housing bushing.

1 Position the extension housing and gasket.

2 Install the extension housing screws.

3 Install the extension housing studs.


124. Position a new extension housing seal withdrain hole in the 6 o’clock position.

4x2 vehicles

122. CAUTION: The lube hole in thebushing must be aligned with the lubegroove in the extension housing.

NOTE: Install the extension housing bushingonly if removed in disassembly.

NOTE: Remove any burrs from the extensionhousing counterbore.

Align the lube hole with the lube groove in 125. Using the special tool, install a new extensionthe extension housing. This groove is located housing seal.at the 3 o’clock position when viewed fromthe rear.

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All vehicles 128. Install the manual control lever.

1 Install the lever.126. CAUTION: The digital transmission 2 Install the nut.

range (TR) sensor must fit flush against theX Tighten to 48 Nm (35 lb-ft).

boss on the case to prevent damage to thesensor.

Install the digital TR sensor.

• Position the digital TR sensor on thetransmission.

• Loosely install the screws.

129. If equipped, install the transmission servo heatshield and nut.

• Tighten to 10 Nm (89 lb-in).

127. CAUTION: Tightening one screwbefore tightening the other can cause thesensor to bind or become damaged.

NOTE: The manual lever must be in theNEUTRAL position.

Using the special tool, align the digital TRsensor and tighten screws in an alternatingsequence.

• Tighten to 10 Nm (89 lb-in).

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130. NOTE: Inspect the O-ring seal for damage. 132. CAUTION: The splines of the inputInstall a new component if damaged. shaft are not the same length on both ends.

The shaft end with the shorter splines goesInstall the output shaft speed (OSS) sensor.into the fluid pump.1 Install the sensor.Install the input shaft.2 Install the screw.


133. Using the special tool, check that the fluidpump gear seal ring is seated.

131. NOTE: Inspect the O-ring seal for damage.Install a new component if damaged.

Install the intermediate shaft speed sensor.

1 Install the intermediate shaft speed sensor.

2 Install the intermediate shaft speed sensorscrew.


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136. Make sure the torque converter is installed to134. CAUTION: Do not damage the fluidspecification.pump gear O-ring seal when installing the

torque converter.

CAUTION: Make sure the converterhub is fully engaged in the front pumpsupport and gear and it rotates freely. Donot damage the hub seal.

CAUTION: If the torque converterslides out, the hub seal can be damaged.

Lubricate the converter hub with cleanautomatic transmission fluid.

137. Lubricate the torque converter pilot hub withmulti-purpose grease.

135. WARNING: The torque converter canfall out if the transmission is tipped. Failureto follow these instructions can result inpersonal injury.

Use the special tools to install the torque138. Install the special tool on the case.converter by pushing and rotating.

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Documents

5r55e Assembly