TRANSMISSION - A4LD - SERVICING THE PLASTIC CAGED OVERDRIVE ONE-WAY CLUTCH - VEHICLES BUILT AFTER 6/9/92 - SERVICE TIP
Publication Date: MAY 18, 1994
1992-1994 AEROSTAR, EXPLORER, RANGER
All A4LD transmissions built after June 9, 1992 contain a plastic-caged overdrive one way clutch (F3TZ-7A089-B) that is not serviceable. The plastic caged clutch, once removed should not be reinstalled into the center shaft. Attempting to install a plastic cage O/D one way clutch into the center shaft will cause damage to the plastic cage. This will result in transmission failure and a repeat repair.
When service is required to a plastic caged O/D one way clutch, install service replacement steel caged O/D one way clutch (E5TZ-7A089-A). Also, the following additional parts are required:
Retaining Washer - E7TZ-7L339-A
O/D Ring Gear - E5TZ-7A153-A (machined to accept retaining washer)
When servicing the plastic-caged O/D one way clutch, the following must be done:
Remove the plastic O/D one way clutch. Through the lube holes in the front of the center shaft, using a drift and soft mallet, carefully drive out the plastic O/D one way clutch and discard, Figure 1.
Figure 1 - Article 94-10-13
Remove retaining ring from O/D ring gear, Figure 2.
Figure 2 - Article 94-10-13
Remove the center shaft from the ring gear and discard the ring gear (the ring gear is not machined to accept a retaining washer).
Clean and inspect the O/D one way clutch outer race (part of the center shaft), and inspect the inner race (part of O/D/ planet carrier). Service as required, Figure 3.
Figure 3 - Article 94-10-13
For service, replace the plastic-caged O/D one way clutch with service replacement steel-caged one way clutch (E5TZ-7A089-A), Figure 4.
Figure 4 - Article 94-10-13
Install a retaining washer (E7TZ-7A089-A) and an overdrive ring gear (E5TZ-7A153-A) in conjunction with the steel-caged one way clutch. The Service ring gear is machined to accept the retaining washer.
Install the steel-caged O/D one way clutch (E5TZ-7A089-A) with the rounded edge facing facing toward bottom of center shaft and shoulder edge facing out, into the center shaft, Figure 5.
Figure 5 - Article 94-10-13
Install the retaining washer (E7TZ-7L339-A) with stamped tabs facing in, into the O/D ring gear. The ring gear is machined to accept the retaining washer, Figure 6.
Figure 6 - Article 94-10-13
Install the center shaft with O/D one way clutch assembly into O/D ring gear with the retaining washer, and install the retaining ring, Figures 7 and 8.
Figure 7 - Article 94-10-13
Figure 8 - Article 94-10-13
For additional service information, refer to the appropriate model year Service Manual, Section 07-01.
O/D One Way Clutch (Steel-Caged)
Overdrive Ring Gear
Center Shaft - All Except 4.0L (May Not Be Needed)