FORD AX4N - Metallic "Clunk" Noise During Reverse Engagement
COMPLAINT: Some models of the 1994-1996 Taurus/Sable and 1995-1996 Continental, equipped with the AX4N transaxle may exhibit a metallic clunk noise coming from the transaxle during engagement to reverse. Upon inspection you will usually find that the lip on the previous design rear planetary support is damaged due to contact with the final drive ring gear and there may also be damage to the number 16 thrust washer on top of the return spring assembly for low/intermediate clutch pack.
CORRECTION: There is now available from Ford Motor Company a new design Rear Planetary Support, under OEM Part Number F6DZ-7A130-A, with the "Lip" removed and an added spacer that should reduce the possibility of final drive ring gear to case contact during reverse engagement. Refer to Figure 1 for illustrations of the previous and new design rear planetary supports. If it is necessary to replace the number 16 thrust washer, you must purchase service package part number F5DZ-7H266-A that includes the return spring assembly for the low/intermediate clutch. It is not available individually (See Figure 2).
The new spacer is installed on top of the case shoulder, after final drive ring gear has been install into the case, and then install the final drive and planetary support as an assembly as shown in Figure 3.
Rear Planetary Support with Spacer (New Design) ...............................F6DZ-7A130-CA
Low/Inter. Return Spring and No. 16 Thrust Washer ............................F5DZ-7H266-A
Figure 1: http://flic.kr/p/dYuD4C
Figure 2: http://flic.kr/p/dYoVyk
Figure 3: http://flic.kr/p/dYuD2S