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HOMESERVICE MANUALSFORD2004ECONOLINE E150, VAN CARGO, 4.6 WREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 250 (AUTOMATIC TRANSAXLE/TRANSMISSION)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES2-4 SERVODISASSEMBLY
2004 Ford Econoline E150, Van Cargo, 4.6 W

2-4 Servo: Disassembly

2004 Ford Econoline E150, Van Cargo, 4.6 WSECTION Disassembly
WARNING: This page is about a different car, the 2002 Mercury Villager. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the second apply piston retainer from the 2-4 servo assembly.
    1. Remove the return spring.
    2. Remove the piston retainer.
      Fig 1: Removing Return Spring
      G03412441Courtesy of FORD MOTOR CO.
  2. Remove the second apply piston from the second apply piston retainer.
    Fig 2: Removing Second Apply Piston From Second Apply Piston Retainer
    G03412442Courtesy of FORD MOTOR CO.
  3. Remove the O-rings from the second apply piston retainer.
    Fig 3: Removing O-Rings From Second Apply Piston Retainer
    G03412443Courtesy of FORD MOTOR CO.
  4. Disassemble the second apply piston.
    1. Remove the E-clip.
    2. Remove the 2-4 servo retainer.
    3. Remove the fourth apply piston return spring.
    4. Remove the apply piston shaft.
      Fig 4: Removing Fourth Apply Piston Return Spring
      G03412444Courtesy of FORD MOTOR CO.
  5. Remove the D-rings from the second apply piston.
    Fig 5: Removing D-Rings From Second Apply Piston
    G03412445Courtesy of FORD MOTOR CO.
  6. Remove the gasket from the fourth apply piston retainer.
    Fig 6: Removing Gasket From Fourth Apply Piston Retainer
    G03412446Courtesy of FORD MOTOR CO.
  7. Remove the fourth apply piston from the fourth apply piston retainer.
    • Apply compressed air to the fluid passage.
      Fig 7: Removing Fourth Apply Piston From Fourth Apply Piston Retainer
      G03412447Courtesy of FORD MOTOR CO.
  8. Remove the fourth apply piston retainer O-rings.
    Fig 8: Removing Fourth Apply Piston Retainer O-Rings
    G03412448Courtesy of FORD MOTOR CO.
  9. Remove the fourth apply piston D-ring.
    Fig 9: Removing Fourth Apply Piston D-Ring
    G03412449Courtesy of FORD MOTOR CO.
RENDER: 1.0x

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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.