307-01-i Automatic Transaxle/Transmission — 6R80 307-01-i

SECTION 307-01 Automatic Transaxle/Transmission — 6R80

CONTENTS PAGE

Transmission ...................................................................................................................................................................... 307-01-2

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Transmission
Special Tool(s)

Dial Indicator Gauge with Holding Fixture

100-002 (TOOL-4201-C)

Drawbar (Heavy Duty Threaded)

204-029 (T77F-1176)

End Play Gauge, Transmission

307-534

Handle, Torque Converter

307-091 (T81P-7902-C)

Installer, Rear Seal 4X4

307-637

Installer, Fluid Pump Seal

307-556

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Installer, Front Wheel Hub Oil Seal

205-276 (T88T-1175-AH)

Installer, Rear Bearing 4X2

307-647

Installer, Shifter Fluid Seal

307-559

Rear Seal Installer 4X2

307-638

Remover/Installer, Rear Bearing 4X4

307-639

Remover, Transmission Fluid Pump

307-553

Retaining Ring Pliers

307-343 (T95P-77001-AHR)

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Material
Item Specification
Motorcraft® MERCON® LV Automatic Transmission Fluid MERCON® LV
XT-10-QLVC
Multi-Purpose Grease ESB-M1C93-B
XG-4 and/or XL-5

Disassembled Views

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Item Part Number Description

1 N800750-S437 Flexplate-to-torque converter nut (4 required)
2 7902 Torque converter
3 7A103 Pump assembly
4 7A248 Front pump oil seal
5 — Pump body (part of 7A103)
6 7A248 Front pump inner oil seal

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Item Part Number Description

7 7N134 Front pump-to-case bolt (13 required)
8 7A103 Front pump assembly
9 W707871-S300 Bolt — attaches pump to pump adapter assembly (11 required)
10 7A248 Front pump outer oil seal
11 7D019 Clutch support fluid seal
12 7L323 Front pump support seal
13 — Forward (A) clutch assembly
14 — Forward (A) clutch rear bushing (part of 7A360)
15 7D014 Front pump selective washer
16 7A360 Forward (A) clutch cylinder and hub assembly
17 7A548 Forward (A) clutch inner piston seal
18 7A548 Forward (A) clutch outer piston seal
19 7A262 Forward (A) clutch piston
20 7A480 Forward (A) clutch piston retaining spring
21 7H360 Forward (A) clutch balance piston assembly
22 7A548 Forward (A) clutch balance piston outer seal
23 7H365 Forward (A) clutch balance piston snap ring
24 7E085 Forward (A) clutch cushion spring
25 7E314 Forward (A) clutch steel plates (externally splined) (quantity model
dependent)
26 7B164 Forward (A) clutch friction plates (internally splined) (quantity
model dependent)
27 7B066 Forward (A) clutch pressure plate
28 7D483 Pressure plate retaining snap ring
29 7D063 Front planetary sun gear (No. 1)
30 7H375 Bearing (T1)
31 — Front planetary carrier assembly snap ring (part of 7A398)
32 7A398 Front planetary carrier assembly
33 7L339 Plate transmission fluid collector
34 7L495 Bearing (T2)
35 — Overdrive (E) clutch assembly
36 7G091 Turbine shaft seals (3 required)
37 7F207 Input shaft
38 — Fluid distributor sleeve (part of 7J006)
39 — Output shaft bushing (part of 7J006)
40 7A548 Overdrive (E) clutch piston outer seal
41 7A548 Overdrive (E) clutch piston inner seal
42 7A262 Overdrive (E) clutch piston
43 7B070 Overdrive clutch piston spring
44 7A548 Balance piston outer seal
45 7H360 Overdrive (E) balance piston
46 7C122 Balance piston snap ring
47 7B442 Overdrive (E) clutch steel plates (externally splined)
48 7B164 Overdrive (E) clutch friction plates (internally splined)
49 7B066 Overdrive (E) pressure plate
50 7D483 Overdrive (E) clutch retaining ring
51 7C096 Bearing (T3)

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Item Part Number Description

52 7F351 Intermediate (C) clutch shaft
53 7H375 Bearing (T4)
54 — Sun gear bushings (part of 7R193) (2 required)
55 7B067 Sun gear hub and shaft assembly
56 7F236 Direct (B) clutch hub
57 7C122 Direct (B) clutch cylinder retaining ring
58 7D483 Direct (B) clutch pressure plate retaining ring
59 — Direct (B) clutch assembly (clutch B)
60 7B066 Direct (B) clutch pressure plate
61 7B164 Direct (B) clutch friction plates (internally splined) (quantity model
dependent)
62 7B442 Direct (B) clutch steel plates (externally splined) (quantity model
dependent)
63 7E085 Direct (B) clutch cushion plate
64 7C096 Roller bearing (T5)
65 7A577 Direct (B) clutch piston retaining ring
66 7A262 Direct (B) clutch balance piston
67 7A548 Direct (B) clutch balance seal
68 7B488 Direct (B) clutch piston return spring
69 — Direct (B) clutch piston
70 7A548 Direct (B) clutch piston outer seal
71 7C099 Direct (B) clutch piston inner seal
72 — Direct (B) clutch hub bushings (part of 7F283) (2 required)
73 — Gear shaft tube sleeve (part of 7F283)
74 7F283 Direct (B) clutch cylinder
75 7D020 Shell cylinder seals (2 required)
76 7D483 Center support retaining ring
77 — Intermediate (C) clutch assembly
78 7D483 Intermediate (C) clutch pressure plate retaining ring
79 7B066 Intermediate (C) clutch pressure plate
80 7B442 Intermediate (C) clutch steel plates (externally splined) (quantity
model dependent)
81 7B164 Intermediate (C) clutch friction plates (internally splined) (quantity
model dependent)
82 7E085 Intermediate (C) clutch pressure plate spring
83 7A577 Intermediate (C) clutch retaining ring
84 7B043 Intermediate (C) clutch ring
85 7A480 Intermediate (C) clutch piston spring
86 7E005 Intermediate (C) clutch piston
87 7F225 Intermediate (C) clutch piston inner seal
88 7F224 Intermediate (C) clutch piston outer seal
89 7F373 Bearing (T6)
90 — Center shaft sleeve (part of support assembly)
91 7B220 Center support keys (2 required)
92 7G199 Center support seals (4 required)
93 7G033 Center support assembly
94 7D404 Low/reverse clutch piston center seal
95 7D403 Low/reverse clutch piston outer seal

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Item Part Number Description

96 7A262 Low/reverse clutch piston
97 7B070 Low/reverse clutch piston return spring
98 7H318 Low/reverse clutch piston retainer
99 7D483 Retainer transmission-snap ring
100 7E085 Clutch disc cushion plate
101 7B442 Low/reverse clutch steel plates (externally splined)
102 7B164 Low/reverse clutch friction plates (internally splined)
103 7B066 Low/reverse clutch pressure plate (select fit)
104 7A089 One-Way Clutch (OWC)
105 7F405 Thrust gear shim (select fit)
106 7C041 Thrust bearing (T7)
107 7D063 Sun gear No. 2
108 7D235 Thrust bearing outer race
109 7D234 Roller bearing (T8)
110 7D063 Sun gear No. 3
111 7D234 Roller bearing (T9)
112 — Roller bearing race (T9)
113 7D006 Rear planetary carrier assembly
114 — Fluid collar rear planetary plate (part of 7D006)
115 7A153 Output shaft ring gear assembly
116 7G178 Thrust Bearing (T10)
117 — Output shaft bushing (part of 7060)
118 7060 Output shaft park gear assembly
119 7N194 Output shaft retaining ring
120 7B368 Bearing (T11)
121 7005 Transmission case assembly (model dependent)
122 7A010 Transmission case fluid fill plug assembly
123 7H398 Transmission case fluid fill plug
124 7A010 Transmission case fluid fill seal
125 7A010 Transmission oil level indicator
126 7034 Transmission case vent assembly (model dependent)
127 7A415 Output shaft bearing assembly (Rear Wheel Drive (RWD))
128 7A415 Output shaft bearing assembly (Four-Wheel Drive (4WD))
129 7A433 Washer
130 7B368 Thrust bearing (T12)
131 7030 Output shaft bearing snap ring 4WD
132 7N357 Slip plane washer
133 7052 Extension housing seal (RWD)
134 7052 Extension housing seal (4WD)
135 7089 Output shaft flange (RWD)
136 7052 Extension housing flange seal
137 7045 Output shaft flange retaining nut (RWD)
138 7E332 Manual valve detent spring
139 W711235-S300 Manual valve detent spring retaining screw and washer
140 7A232 Park pawl actuator rod
141 7A441 Park pawl

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Item Part Number Description

142 7D070 Park pawl return spring
143 7D071 Park pawl shaft
144 7H398 Plug assembly transmission case housing
145 7G101 Park rod actuating plate
146 W711235-S300 Park pawl abutment retaining screw and washer
147 W708455-S441 Manual control lever nut
148 7A256 Manual control lever
149 7B498 Manual control lever shaft seal
150 7C493 Manual control lever shaft
151 7A209 Manual control lever shaft spacer
152 7A115 Manual valve detent lever assembly
153 7G100 Manual valve detent lever retaining pin
154 7F277 OWC bias spring
155 7H322 Thermal bypass valve
156 7F401 Front pump adapter seal
157 7A100 Main control assembly
158 — Main control valve body assembly (part of 7A100)
159 7Z490 Main control valve body separator plate
160 — Lower main control valve body (part of 7A100)
161 7G276 Molded leadframe
162 7G276 Bulkhead connector sleeve
163 — Transmission fluid filter seal (part of 7A098)
164 7A098 Transmission fluid filter
165 — Transmission fluid pan magnet
166 7A191 Transmission fluid pan gasket
167 7A194 Transmission fluid pan
168 W500214-S437 Transmission fluid pan bolt

NOTE:
Clutch plate quantity is model dependant based on engine displacement. Refer to Clutch Plate Quantity chart in the Specifications portion of this section.

All vehicles
1. Install the park detent spring and the 2 bolts.
• Tighten to 12 Nm (106 lb-in).

2. Position the park pawl and spring into the case and install the park pawl pin.
1 Park pawl
2 Park pawl return spring

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3 Park pawl pin

3. Install the park pawl pin bolt.

• Tighten to 23 Nm (17 lb-ft).

4. Install a new manual control lever shaft seal on the Shifter Fluid Seal Installer.

5. Using the Shifter Fluid Seal Installer, install the manual control lever shaft seal.

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6. Assemble the manual control lever detent plate assembly and park pawl actuator rod.

7. Position the manual valve detent lever and park pawl actuator rod assembly in the transmission case.

8. Position the manual control lever spacer in place and slide the manual control lever shaft into the case and the manual lever detent plate.
1 Manual control lever spacer
2 Manual control lever shaft
3 Manual control lever detent plate

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9. Align the roll pin hole in the manual control lever detent plate with the roll pin hole in the manual control lever shaft and install a new roll pin using a
suitable tool.

10. Install the park rod actuating plate and the 4 bolts.
• Tighten to 12 Nm (106 lb-in).

Four-Wheel Drive (4WD) vehicles

11. If removed, position a new bearing on the Needle Bearing Installer. Install the bearing with the flat bearing surface facing down and the rounded
bearing surface facing up so that when installed, the flat surface is on the snap ring side and the rounded surface is on the transmission case side.
1 Rounded bearing surface facing up
2 Flat bearing surface facing down

12. Using the Needle Bearing Installer, the Drawbar and the Front Wheel Hub Oil Seal Installer, install the bearing in the transmission case.

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13. Install the snap ring.

Rear Wheel Drive (RWD) vehicles

14. Install the bearing on the Rear Bearing 4X2 Installer.

15. Assemble the Front Wheel Hub Oil Seal Installer and the Rear Bearing 4X2 Installer on the Drawbar and install the bearing in the transmission case.

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16. Position the thrust bearing spacer.

17. Using the Rear Bearing 4X2 Installer and a press, press the thrust bearing spacer in place.

18. Install the T12 thrust bearing.

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All vehicles
19. Install the T11 bearing, on the planetary ring gear and output shaft assembly.

20. Install the rear planetary ring gear and output shaft assembly.

21. Install the T10 thrust bearing on the output shaft assembly.

22. Install the T9 roller bearing race into the bottom of the carrier.

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23. Install the top T8 and the bottom T9 roller bearings onto the sun gear.

24. NOTE:
When installing the sun gear, make sure that the TAPERED EDGE is facing UP toward the torque converter housing.

Install the sun gear into the planetary assembly.

25. NOTE:
Be sure the bearing race is installed in the sun gear.

Install the low/reverse sun gear and bearing race into the planetary carrier with the race side facing down.
1 Low/reverse sun gear
2 Bearing race

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26. NOTE:
Place the manual control lever in PARK when installing the rear planetary gearset to hold the rear ring gear stationary.

Install the planetary carrier.

27. NOTE:
Friction and steel plate quantity are model dependent and vary based on engine displacement. For additional information, refer to the Clutch Plate
Quantity Chart in the Specifications portion of this section.

Soak the low/reverse clutch plates in clean automatic transmission fluid.

28. Install the low/reverse clutch plates, starting with the pressure plate and alternating between the friction and steel plates and ending with the wave
spring plate on the top.

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29. NOTE:
Inspect the T7 thrust bearing and selective shim for damage or scoring.

Install the T7 thrust bearing and the selective shim.

30. NOTE:
Align the One-Way Clutch (OWC) in the transmission case so the bias spring fits into the transmission case.

Install the OWC as shown so the bias spring can be installed as shown.

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31. Install the bias spring.

32. NOTE:
Make sure that when installing the center support the feed holes on the center support are lined up with the feed holes in the case.

Install the center support into the case.

33. NOTICE:
Install the snap ring with the beveled surface facing up and the snap ring gap in the 3 o'clock or the 9 o'clock position.

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NOTE:
Rotate the case to a horizontal position.

Using the Retaining Ring Pliers, install the center support snap ring. Using a suitable tool, make sure the snap ring is fully seated.

4WD vehicles
34. Install the seal protector provided with the new output shaft seal on the output shaft.

35. Slide the output shaft seal over the output shaft seal protector onto the output shaft. Remove the output shaft seal protector.

36. Using the Rear Seal 4X4 Installer, install the output shaft seal.

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RWD vehicles
37. Rotate the transmission to the vertical position and install the slip plane washer.

38. Position a new output shaft seal on the Rear Seal Installer 4X2.

39. Using the Rear Seal Installer 4X2, install the output shaft seal.

40. Install the output shaft flange and the extension housing flange seal.

41. Loosely install a new output shaft flange retaining nut.

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RWD vehicles
42. Install the Dial Indicator Gauge with Holding Fixture on the transmission case and position the plunger on the output shaft flange.

43. NOTE:
Loosely install the flange nut or an inaccurate reading may be recorded.

Using the Dial Indicator Gauge with Holding Fixture, lift up on the output shaft flange and record the reading. The reading should be within 0.6-0.9
mm (0.024-0.035 in).
• If the reading is not within specification, install a different (either thinner or thicker) selective shim.

44. Tighten the output shaft flange nut.

• Tighten to 80 Nm (59 lb-ft).
• After installing the new output shaft flange nut, stake the slots to prevent it from coming loose.

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4WD vehicles
45. Install the Dial Indicator Gauge with Holding Fixture on the transmission case and position the plunger on the output shaft.

46. Using the Dial Indicator Gauge with Holding Fixture, lift up on the output shaft and record the reading. The reading should be within 0.15-0.35 mm
(0.005-0.013 in).
• If the reading is not within the specification, install a different (either thinner or thicker) select fit thrust gear shim.

All vehicles

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47. Rotate the transmission in the vertical position with the torque converter housing facing up and install the T6 bearing.

48. Install the direct (B) clutch assembly.

49. Install the T5 roller bearing on the direct (B) clutch assembly.

50. Install the forward (A)/overdrive (E) clutch assembly.

51. Install the selective shim.

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52. If the front pump was not disassembled and assembled, install a new front pump O-ring seal and lubricate it with petroleum jelly.

53. Install a new front pump seal on the Fluid Pump Seal Installer.

54. Using the Fluid Pump Seal Installer, install the front pump seal.

55. Install the Transmission Fluid Pump Remover on the front pump.

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56. Lubricate the transmission case pump bore with petroleum jelly. Using the Transmission Fluid Pump Remover, position the pump assembly in the
case and rotate the pump to insert the pump splines into the front planetary sun gear. Rotate the pump to align the pump-to-case bolts and push the
pump into the case.

57. Install 13 new front pump-to-case bolts and washers. Tighten in a crisscross pattern.
• Tighten to 10 Nm (89 lb-in).

58. Install the Transmission End Play Gauge on the input shaft to measure the end play.
• Tighten the wing nut.

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59. Install the Dial Indicator Gauge with Holding Fixture on the Transmission End Play Gauge.
• Push down on the Transmission End Play Gauge and zero the Dial Indicator Gauge.
• Lift up on the Transmission End Play Gauge and record the measurement on the Dial Indicator Gauge. The measurement should be between
0.2-0.4 mm (0.008-0.015 in). If the measurement is not within specification, install a new selective front pump shim.
• Measure the original shim, install a thinner or a thicker shim to achieve the correct measurement.

60. Rotate the transmission in the horizontal position with the main control area facing up and install 4 new center support feed tubes.
1 Black feed tubes
2 Green feed tube
3 Blue feed tube

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61. NOTE:
Make sure the transmission fluid filter seal has been removed. If it has not, use a suitable pick and remove the seal.

NOTE:
Add 0.118L (4 oz) of clean transmission fluid to prime the pump.

Install the front pump adapter seal and prime the fluid pump.

62. Install the thermal bypass valve into the case.

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63. Align the guide pins in the alignment holes in the transmission case and position the mechatronic assembly in place.
1 Alignment holes
2 Guide pins

64. NOTE:
The mechatronic assembly will not lay flush on the case, this is a normal condition with the rubber feed tubes, the bolts will pull the mechatronic
assembly down.

Slightly lift the mechatronic assembly and align the manual valve in the manual valve linkage and position the mechatronic in place.

65. Install the 11 mechatronic assembly bolts and tighten in the sequence shown.
• Tighten to 8 Nm (71 lb-in).

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66. With the release tab up and unlocked, push the outer shell of the bulkhead electrical connector into the transmission. Make sure the bulkhead
connector is fully seated into the molded leadframe.

67. Press down on the tab and lock the outer shell of the bulkhead electrical connector in place. Make sure the locking tab is securely locked.

68. Install a new transmission fluid filter.

69. NOTE:
The fluid pan gasket can be reused if not damaged.

Install a new transmission fluid pan gasket if required.

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70. Install the transmission fluid pan and transmission fluid pan bolts. Tighten in a crisscross pattern.
• Tighten to 12 Nm (106 lb-in).

71. Using the Torque Converter Handle, install the torque converter.

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