Removal and Installation

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Special Service Tools

REMOVAL AND INSTALLATION
Transmission-F-150-F-250 (4X2)
Removal
1. Remove the floor mat, the body floor pan cover, gearshift lever shift ball and boot as an assembly. Remove the isolator pad.
2. Raise the vehicle and position safety stands. Position a transmission jack such as Rotunda 006-00017, or equivalent under the transmission, and disconnect the speedometer cable.
3. Disconnect the back-up lamp switch located at the rear of the gear shift housing cover.
4. Disconnect the driveshaft or coupling shaft and clutch actuator from the transmission and wire it to one side.
5. Disconnect the transmission mount and remove the transmission crossmember.
6. Remove the transmission attaching bolts.
7. Move the transmission to the rear until the input shaft clears the clutch housing. Lower the transmission.

Installation

1. Place the transmission on a transmission jack, install guide studs in the clutch housing and raise the transmission until the input shaft splines are aligned with the clutch disc splines. The clutch release bearing and hub must be properly positioned in the release lever fork.
2. Slide the transmission forward on the guide studs until it is in position on the clutch housing. Install the attaching bolts and tighten them to 48-67 N.m (35-50 ft-lb). Remove the guide studs and install the two lower attaching bolts.
3. Install the crossmember and transmission mount. Tighten fasteners to specifications.
4. Connect the speedometer cable and clutch actuator.
5. Install the bolts attaching the front U-joint of the coupling shaft to the transmission output shaft flange. Tighten the bolts and nuts to specifications Tighten the U-bolt nuts to 11-20 Nm (8-15 ft-lbs).
6. Connect the back-up lamp switch.
7. Install the shift lever, boot and shift ball as an assembly and lubricate the spherical ball Seat with Long-Life Lubricant C1AZ-1959O-BA (ESA-M1C75-B) or equivalent.
8. Install the isolator pad. Install the floor pan cover and floor mat.

Transmission F-150-F-250 (4X4) Bronco

Removal
1. Open door and cover seat.
2. Remove the four screws holding the floor mat.
3. Remove the eleven screws holding the access cover to the floor pan. Place the shift lever in the reverse position and remove the cover.
4. Remove the insulator and dust cover.
5. Remove the transfer case shift lever, shift bail and boot as an assembly.
6. Remove transmission shift lever, shift bail and boot as an assembly.
7. Raise the vehicle on a hoist.
6. Remove the drain plug and drain the transmission.
9. Disconnect the rear driveshaft from the transfer case and wire it out of the way.
10. Disconnect the front driveshaft from the Transfer case and wire it out of the way.
11. Remove the shift link from transfer case.
12. Remove the speedometer cable from the transfer case.
13. Position a transmission jack under the transfer case. Remove the six bolts holding the transfer case to the transmission and lower the transfer case from the vehicle.
14. Remove the eight bolts that hold the rear support bracket to the transmission.
15. Position a transmission jack under the transmission and remove the rear support bracket and brace.
16. Remove the four bolts that hold the transmission the bell housing.
17. Remove the transmission from the vehicle.

Installation
1. Place the transmission on a transmission jack and install it in the vehicle installing two guide studs in the bell housing top holes, to guide the transmission into position.
2. Install the two lower bolts. Remove the guide studs and install the upper bolts.
3. Place the rear support bracket in position and install the eight retaining bolts.
4. Install the two bolts at the rear support insulator bracket. Remove the transmission lack.
5. Position the transfer case on the transmission jack and install the six retaining bolts and gasket. Position the transfer case on the transmission and tighten the bolts as listed in the appropriate transfer case section.
6. Install the transfer case shift link.
7. Position and install the speedometer cable.
8. Remove wire and connect front driveshaft.
9. Remove wire and connect rear driveshaft.
10. Fill transfer case (as required) with MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or-DDX,E4AZ-19582-B (ESP-M2C 166-H) or equivalent and fill the manual transmission with Standard Transmission Lubricant (SAE 80W), D8DZ-19C547-A (ESP-M2C83-C) lubricant or equivalent.
11. Lower vehicle.
12. Remove fabricated dirt shield and prepare gasket area.
13. Position gasket and shift cover.
14. Install two pilot bolts, then install remaining shift cover retaining bolts.
15. Install transfer case shift lever, shift ball and boot as an assembly and transmission shift lever, shift ball and boot as an assembly.
16. Install dust cover and insulator.
17. Install access cover to floor pan screws.
18. Install the four floor mat screws.
19. Install the four boot area screws.