ATSG AXOD Technical manual

INDEX
Copyright © ATSG 2002
AXOD/AXODE (AX4S)
UPDATE HANDBOOK
HYDRAULIC SYSTEM CHANGES .................................................................................................................. 4
SPACER PLATE IDENTIFICATION ................................................................................................................. 9
PUMPAND VLAVE BODYGASKET IDENTIFICATION ............................................................................. 14
VALVE BODY CHECKBALLLOCATIONS ..................................................................................................... 21
OILPUMPCHECKBALLLOCATIONS .......................................................................................................... 22
VALVE BODYVALVE LOCATIONSAND IDENTIFICATION ..................................................................... 26
PREMATURE PLANETARY FAILURE ............................................................................................................ 34
INTERMEDIATE CLUTCH PACK CHANGES ............................................................................................... 40
NEW STEELFORWARD CLUTCH PISTON .................................................................................................. 48
HARSH COASTDOWN SHIFT .......................................................................................................................... 49
SPROCKET RATIO IDENTIFICATION (ALL) ............................................................................................... 51
NEW DESIGN OIL PUMPBEARING WITH INTEGRALSEAL................................................................. 56
ACCUMULATOR SPRING IDENTIFICATION (ALL) .................................................................................. 58
LOW SPRAG FREEWHEEL DIRECTION ..................................................................................................... 62
FORWARD CLUTCH WAVE PLATE CHANGE ............................................................................................. 64
FORWARD CLUTCH PACKAND LOW SPRAG OUTER RACE CHANGE ............................................. 68
NEW DESIGN INPUT PLANETARYAND SUN SHELL............................................................................... 72
NO MOVEMENT OR NO TCC .......................................................................................................................... 75
OILPUMPCHECKBALLLOCATION CHANGES ........................................................................................ 76
TORQUE CONVERTERAND TURBINE SHAFT SPLINE CHANGES ....................................................... 79
VALVE BODYVALVE LOCATIONSAND IDENTIFICATION ..................................................................... 80
VALVE BODYAND OIL PUMPSPACER PLATE IDENTIFICATION ........................................................ 88
OILPUMPAND VALVE BODY GASKET IDENTIFICATION ..................................................................... 89
VALVE BODY CHECKBALLLOCATION CHANGES .................................................................................. 92
PREMATURE PLANETARY FAILURE ............................................................................................................ 95
CHAIN COVERAND THRUSTWASHER CHANGES ................................................................................... 96
1991-1992 ELECTRICALDIAGNOSIS ........................................................................................................... 100
NEW DESIGN CHAIN COVER KIT FOR NEW CASE CONNECTOR ..................................................... 103
1993-UPELECTRICALDIAGNOSIS .............................................................................................................. 104
NEW DESIGN TCC SOLENOID ...................................................................................................................... 106
VEHICLE SPEED SENSOR CHANGES ......................................................................................................... 108
PRESSURE TAP LOCATIONS ......................................................................................................................... 111
PRESSURE CONTROLPROBLEM DIAGNOSIS ......................................................................................... 112
WINDSTARAND TAURUS SPACER PLATE IDENTIFICATION .............................................................. 116
LATEST CHAIN COVERAND GASKET CHANGE (NO REVERSE) ........................................................ 119
AXOD AND AXODE
AXODE
AUTOMATIC TRANSMISSION SERVICE GROUP
18639 S.W. 107TH AVENUE
MIAMI, FLORIDA 33157
[phone]
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INTRODUCTION
DALE ENGLAND
FIELD SERVICE CONSULTANT
ED KRUSE
TECHNICAL CONSULTANT
WAYNE COLONNA
TECHNICAL SUPERVISOR
PETER LUBAN
TECHNICAL CONSULTANT
JIM DIAL
TECHNICAL CONSULTANT
GREGORY LIPNICK
TECHNICAL CONSULTANT
JERRY GOTT
TECHNICAL CONSULTANT
JON GLATSTEIN
TECHNICAL CONSULTANT
DAVID CHALKER
TECHNICAL CONSULTANT
MIKE SOUZA
TECHNICAL CONSULTANT
ROLAND ALVAREZ
TECHNICAL CONSULTANT
GERALD CAMPBELL
TECHNICAL CONSULTANT
NopartofanyATSGpublicationmaybereproduced,storedinanyretrievalsystemortransmittedinanyformor
by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise,
without written permission of Automatic Transmission Service Group. This includes all text illustrations,
tablesandcharts.
The information and part numbers contained in this booklet have
been carefully compiled from industry sources known for their
reliability, but ATSG does not guarantee its accuracy.
Copyright © ATSG 2002
Updated
October, 2002
Since the introduction of the Ford AXOD transaxle in model year 1986, there have been many major
engineering design changes that have affected many of the parts used in theAXOD transaxle. This version of
the AXOD "Update Handbook" begins with the 1986 model year and will explain each change, the parts
affected by the change, and any parts interchange problems created by the change. This booklet is an updated
versionoftheoriginal.
This updated version of the AXOD "Update Handbook" will also cover the changes that occured in the 1991
model year, when electronic controls were adapted to the AXOD transaxle, making it an AXODE, and now
called an AX4S transaxle. We have included the changes on the AX4S transaxle up through and including
modelyear2002.
WewishtothankFordMotorCompanyfortheinformationandillustrationsthathavemadethispossible.
1
AUTOMATIC TRANSMISSION SERVICE GROUP
18639 S.W. 107TH AVENUE
MIAMI, FLORIDA 33157
[phone]