4R44E/4R55E Disassembly.

[church]

Transmission, Automatic, 4R44E, 4R55E 1996 Aerostar, Ranger, Explorer

DISASSEMBLY

--------------------------------------------------------------------------

Transmission

Disassembly

1.

WARNING: DO NOT REMOVE THE TORQUE CONVERTER OR TRANSFER CASE FROM THE TRANSMISSION WHILE STILL ON THE JACK. DOING SO COULD CAUSE THE TRANSMISSION TO FALL OFF THE JACK.

Relocate the transmission to the top of a flat workbench.

2. NOTE: for transfer case service. < link will be added later >



If the vehicle has a transfer case, use a 13mm socket to remove the five transfer case-to-extension housing screws. Remove the transfer case and set aside for assembly.

3.

WARNING: THE TORQUE CONVERTER IS HEAVY, ESPECIALLY WHEN FULL OF FLUID.

Remove the torque converter using Torque Converter Handles T81P-7902-C.

4. NOTE: The splines on the input shaft are not the same on both ends. The end with the shorter spline goes into the assembly.

Remove the input shaft.

5. Remove the extension housing seal using Seal Remover TOOL-1175-AC and Impact Slide Hammer T50T-100-A.

6. NOTE: Remove the extension housing bushing only if service is required.
Inspect the extension housing bushing and driveshaft slip-yoke for nicks, gouges, scoring and wear.
Remove the extension housing bushing using Extension Housing Bushing Remover T77L-7697-E.

7.

CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.

Use a 17mm socket to remove the five M10 x 30mm extension housing-to-transmission case screws and stud.

8. Remove the parking pawl, parking pawl return spring and parking pawl shaft.

9.

CAUTION: The parking pawl actuating rod must slip freely into the clearance hole in the adapter plate.

NOTE: See the Special Service Tool section for a drawing of this optional adapter plate.

Use the four M10 x 30mm extension housing to transmission case screws to attach the adapter plate to the transmission.

10. Attach the fixture arm assembly (part of T57L-500-B) with two 7/16 x 2-inch bolts and nuts.

 

[church]

11.

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

Install the transmission assembly to Bench-Mounted Holding Fixture T57L-500-B. Rotate to the position shown. Place a drain pan under the assembly.

12. NOTE: A transmission heat shield is on all 4.0L vehicle.

Remove the M6 x 1.0 transmission heat shield nut from the studded screw.

13. Carefully pry the transmission heat shield off of the fluid pan rail near the retaining clips.

14.

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

Rotate the transmission assembly so the converter housing is facing up.

15.Remove the manual control outer lever nut and manual control outer lever.

16. Remove the two M6 x 25 transmission range (TR) sensor screws and remove the TR sensor.

17.

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

Rotate transmission assembly so that the fluid pan is facing up.

18.

CAUTION: Do not reuse the fluid pan gasket.

Use a 13mm socket to remove the eighteen M8 x 1.4mm fluid pan screws. Remove the fluid pan and fluid pan gasket. Discard the fluid pan gasket.


Fluid Pan Removal

Fluid Pan Filter Removal

19. Use a 10mm socket to remove the M6 x 55mm fluid pan filter assembly screw. Remove and discard the fluid pan filter assembly.

20. Carefully lift up on the wire loom guide and protector. Disengage the retaining pins from the solenoid clamps.

 

[church]

21. Disconnect the six solenoid connectors from the solenoids by carefully pulling upward and wiggling side to side.

22. Use a 10mm socket to remove the M6 x 30mm manual valve detent spring screw. Remove the manual valve detent spring.

23. Use a 10mm socket to remove the four M6 x 20mm reverse servo cover screws. Remove the reverse servo cover, reverse servo piston and rod and reverse servo.

24.

CAUTION: To prevent solenoid valves from falling out, do not remove the two screws shown below.

NOTE: Refer to the Main Control disassembly and assembly in this section.


Use a 10mm socket to remove the seventeen M6 x 40mm, four M6 x 45mm, two M6 x 35mm and one M6 x 30mm main control valve body screws.

25. Remove the main control assembly.

26. NOTE: The J-hook must be in the appropriate hole for the servo being removed.

Install Servo Cover Compressor T95L-77028-A over the intermediate servo cover at the fluid pan rail with tool stamping facing up. Tighten the screws.

27. Using a 1/2-inch wrench, tighten the nut on the J-hook until there is a gap between the servo cover and the snap ring.

28. Carefully remove the servo cover retaining ring.

29.

CAUTION: The servo cover is under spring tension.

Carefully back off the nut on the J-hook until the servo spring is unloaded.

 

[church]

30.

WARNING: AIR PRESSURE SHOULD NOT BE GREATER THAN 138 KPA (20 PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. THE PISTON ASSEMBLY CAN POP OUT UNEXPECTEDLY DUE TO SPRING PRESSURE BEHIND THE PISTON. DO NOT STAND DIRECTLY IN FRONT OF THE PISTON.

NOTE: Light tapping on the cover and case, or air pressure applied on the release side may be needed. Use 4R44E/4R55E Transmission Test Plate T95L-77000-AH and Transmission Test Plate Gasket T95L-7006A.

NOTE: Tag the spring, piston and cover assembly. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.

Remove the intermediate servo cover, piston and spring.

31. Remove Servo Cover Compressor T95L-77028-A.

32. NOTE: The J-hook must be in the appropriate hole for the servo being removed.

Install Servo Cover Compressor T95L-77028-A over the overdrive servo cover at the fluid pan rail. Tighten the screws.

33. Using a 1/2-inch wrench, tighten the nut on the J-hook until there is a gap between the servo cover and the retaining ring.

34. Carefully remove the servo cover retaining ring.

35.

CAUTION: The servo cover is under spring tension.

Carefully back off the nut on the J-hook until the servo spring is unloaded.

36.

WARNING: AIR PRESSURE SHOULD NOT BE GREATER THAN 138 KPA (20 PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. THE PISTON ASSEMBLY CAN POP OUT UNEXPECTEDLY DUE TO SPRING PRESSURE BEHIND THE PISTON. DO NOT STAND DIRECTLY IN FRONT OF THE PISTON.

NOTE: Light tapping on the cover and case, or air pressure applied on the release side may be needed. Use 4R44E/4R55E Transmission Test Plate T95L-77000-AH.

NOTE: Tag the spring, piston and cover assembly. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.



Remove the overdrive servo cover, piston and spring.

37. Remove Servo Cover Compressor T95L-77028-A.

38.

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

Rotate the transmission assembly with the converter housing facing up.

39.

CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.

Remove the overdrive and intermediate band locknuts and discard. Back off the band adjusting screws.

 

[church]

40.

CAUTION: Throw the screws away. The screws are not reusable for assembly.

Use a 17mm socket to remove the eight M10 x 33mm converter housing-to-case screws. Discard the screws.

41. NOTE: Rotate and lift the converter housing so that the clutch assemblies will stay in place.

Remove the converter housing and fluid pump support and gear assembly.

42. NOTE: Refer to Converter Housing And Pump Assembly under subassemblies for service information.

Remove the fluid pump gasket and No. 1 fluid pump thrust washer and discard the gasket. Tag the No. 1 fluid pump thrust washer for identification.

43. Remove overdrive band adjusting screw. Compress the overdrive band around the overdrive brake and coast clutch drum. Remove the overdrive band anchor strut.

44.

CAUTION: Identify which end of the overdrive band is the anchor side or the apply side.

Remove the overdrive band.

45. Remove the overdrive brake and coast clutch drum.

46. Remove the overdrive band apply strut.

47. NOTE: Tag and identify the overdrive lever for assembly. The overdrive lever has a letter stamped into its side.

NOTE: The overdrive band actuating lever shaft is longer than the intermediate shaft.

Remove the overdrive band actuating lever shaft.

48.

CAUTION: Do not bend the exciter wheel.

NOTE: No.12 and No. 2 thrust bearings are in this assembly.

Remove the planetary gear overdrive carrier.

49. Remove the servo band lever and overdrive control bracket.

 

[church]

50. Remove the overdrive ring gear, overdrive one-way clutch and overdrive center shaft assembly.

51. NOTE: Tag and identify the No. 3 center shaft thrust bearing assembly for assembly.


Remove the No. 3 center shaft thrust bearing assembly.

52.

CAUTION: The center support locking nut could fall into the remaining assembly if not removed.

Use a 5mm Allen wrench to remove the M6 x 20mm center support capscrew. Remove the locking nut from the center support.

53.

CAUTION: Do not pry on other wires or damage the connector or case surface.

Carefully disconnect the turbine shaft speed (TSS) sensor connector from the 16-pin case connector.

54. Carefully remove TSS sensor connector wires from the retaining slot on the 16-pin case connector.

55. Use a T30 Torx® bit to remove the TSS screw.

56. Carefully route the TSS connector and wiring into the transmission through the opening in the case. Remove the TSS.

57.

CAUTION: Do not overstretch the case connector retaining ring.

Use a screwdriver to carefully remove the case connector retaining ring.

58.

CAUTION: Do not damage the connector or harness.

Carefully push down on the top of the connector until it stops. Depress the tab on the back side of the connector and push down on the connector. Remove the connector and harness through the bottom of the case.

59. Remove the center support retaining ring.

 

[church]

60. Remove the center support by pulling evenly around the center support web.

61. NOTE: Tag and identify the No. 4 intermediate brake drum thrust bearing for assembly.

Remove the No. 4 intermediate brake drum thrust bearing.

62. Remove the intermediate band anchor strut through the bottom of the case. Remove intermediate band adjusting screw.

63.

CAUTION: Identify which end of the intermediate band is the anchor side or the apply side.

Remove the intermediate band.

64. Remove the intermediate band apply strut.

65. NOTE: The intermediate band actuating lever shaft is shorter than the overdrive band actuating lever shaft.

Remove the intermediate band actuating lever shaft.

66. NOTE: Tag and identify the intermediate band servo lever for assembly. The intermediate band servo lever has a letter stamped on its side for identification.

Remove the intermediate band servo lever.

67.

CAUTION: Make sure the lock pin on Bench-Mounted Holding Fixture T57L-500-B is secure.

Rotate the transmission so the fluid pan surface is facing up.

68. NOTE: The No. 5 forward clutch cylinder thrust washer may come out with the intermediate brake and direct clutch drum.

Remove the intermediate brake and direct clutch drum.

69. Remove the No. 5 forward clutch cylinder thrust washer.

 

[church]

70. NOTE: The No. 5 forward clutch cylinder thrust washer may come out with the forward clutch cylinder.

Remove the forward clutch cylinder.

71. Remove No. 6A forward ring gear hub thrust bearing assembly.

72. Remove the forward ring gear and forward ring gear hub.

73. NOTE: Check black oxidized side during removal to ensure correct placement during reassembly. Black oxidized side must be toward planetary assembly. The green side must face up.

Remove the No. 7 forward planetary thrust bearing.

74. NOTE: The forward planetary assembly is model dependent.

Remove the forward planetary assembly.

75. Remove the input shell with forward sun gear.

76. NOTE: 4.0L engines do not have this retaining ring.

Remove the reverse planetary retaining ring.

77. NOTE: The No. 8 reverse planetary carrier thrust washer is model dependent.

NOTE: Tag and identify the No. 8 reverse planetary carrier thrust washer for assembly.

Remove the reverse planetary assembly and No. 8 reverse planetary carrier thrust washer.

2.3L, 3.0L

4.0L

78. NOTE: The No. 9 reverse planetary carrier thrust washer is model dependent. Tag and identify for reassembly.

Remove the No. 9 reverse planetary carrier thrust washer.

79. NOTE: The output shaft sleeve is on 4.0L applications only.

Remove the output shaft sleeve.

 

[church]

80.

CAUTION: Discard the output shaft retaining ring. A new retaining ring must be used for assembly.

Remove the output shaft retaining ring from inside the case on the output shaft.

81. Remove the output shaft ring gear and output shaft hub.

82. NOTE: The No. 10 output shaft hub thrust washer is model dependent.

NOTE: Tag and identify the No. 10 output shaft hub thrust washer for assembly.

Remove the No. 10 output shaft hub thrust washer.

83. NOTE: The inner race of the rear one-way clutch is not removable. It is serviced in the case.

Remove the reverse brake drum and the one-way clutch assembly.


Reverse Brake Drum and One-Way Clutch Assembly Removal — 2.3L, 3.0L

Reverse Brake Drum and One-Way Clutch Assembly Removal — 4.0L

84. Remove the reverse band.

85.

CAUTION: The output shaft is model dependent. The 4.0L output shaft does not have lube holes.

Remove the output shaft.

86. Remove the park gear.

87. NOTE: Tag and identify the No. 11 output shaft thrust washer for assembly.

Remove the No. 11 output shaft thrust washer.

88.

CAUTION: To avoid damage, make sure wrench does not strike the manual valve inner lever pin.

Remove the manual valve inner lever nut.

89. Remove the manual valve inner lever and parking pawl actuating rod assembly.

 

[church]

90.

CAUTION: Do not damage the case fluid pan rail.

Using a small hammer and drift, tap lightly on each side of the manual control lever shaft retaining pin (two or three times). This will loosen the pin prior to removal.

91.

CAUTION: Do not damage the case fluid pan rail.

Remove the manual control lever shaft retaining pin with a narrow, sharp edged screwdriver from the side as shown.

92. Remove the manual control lever shaft.

93.

CAUTION: Do not damage the bore.

Remove the manual control lever seal.

 

[Jack Flash]

HUH ?

hope you haven't violated any copyright laws by posting all those pages...

,
,

J...was bit by a cease & desist order years ago after posting copyrighted materials..

 

[church]

Violated Copyrights? lol. that made me laugh. but no. To violate copyright laws id have to state a link to where you can get the software, and or distribute the software as it is, which im not. the post i made was for reference since this forum lacks info on the 4R44E.

P.S. © 2001 Ford Motor Company. All rights reserved.
If it makes you feel better.

 

[BrooklynBay]

Thanks for taking the time to make this thread! It's now a sticky on the top of the transmissions & transfer cases section. We didn't have too much on the 4R44E/4R55E until now. A link was added to # 69 in my list of useful threads.

 

[95exploresport]

Thanks for taking the time to make this thread! It's now a sticky on the top of the transmissions & transfer cases section. We didn't have too much on the 4R44E/4R55E until now. A link was added to # 69 in my list of useful threads.

Good # in useful threads, thank-you Church for your input

I may need this if I really get hard up and need to overhaul my 4R44E

 

[95exploresport]

Guess I'm hard up, I bought a kit and doing the overhaul.

These directions have been very handy as I am in the middle of the overhaul and have not skipped a beat with these very detailed directions.
Thanks again.

 

[jh53]

heres my problem i rebuilt a 4r55e trans evrything works good except ihave no fluid coming out of the cooling lines

 

[BrooklynBay]

 

[95exploresport]

Do you think you may have damaged the pump when reassembling it to the engine?

 

[wendorms]

1999 4r44e

Howzit, all? Does anyone know how to turn in the motor module or solenoid to make my aging 4r44e shift a bit more solid? I looked and it appears to be behind a cat converter with no possible access.
Thanks in advance..

Wendl Ormsby
Covina, CA
wendorms@gmail.com

 

[PopRichie77]

All solenoids are inside the pan, there is no access on the outside and what you are asking is not recommended. The slightest tweek to much can screw things up and you can't check till it is all back together.
You should have started another post and not added to this one.