Installation

Special Tools:

1. Inspect the wiring harness and the connectors for damage, terminal condition, corrosion and seal integrity. Repair or replace as required.

CAUTION: Prior to the installation of the transmission the fluid coolers, cooler lines and the cooler bypass valve will need to be cleaned.

2. Lubricate the torque converter pilot hub.
- Use Ford Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-13.

CAUTION: Prior to installation of the transmission assembly, the torque converter pilot hub must be properly lubricated.





3. Position, then raise the transmission into the vehicle while watching for obstructions.

CAUTION: If a safety strap is being used to hold the transmission to the High-Lift Transmission jack, place the strap behind the Cooler Bypass Valve (CBV) to prevent damage to the cooler bypass valve.

NOTE: Prior to installation, inspect the transmission wiring harness and the connectors for damage, terminal condition, corrosion and seal integrity. Repair or replace as required.

NOTE: Due to the proximity of the exhaust pipe, the bolt must be installed into the converter housing mounting hole above the starter motor mounting area prior to raising the transmission into the vehicle.





4. Align the (A) torque converter studs with the mounting holes in the (B) flywheel. Install the (C) transmission to the (D) engine.

CAUTION: Do not allow the torque converter drive flats to disengage from the pump gear. Use care not to damage the flywheel and the converter pilot. The torque converter must rest squarely against the flywheel, indicating the converter pilot is not binding in the crankshaft.








5. Install and alternately snug the 2 transmission-to-engine retaining bolts.





6. Install, snug, then tighten the new torque converter-to-flywheel nuts.
7. Alternately tighten the transmission-to-engine bolts.





8. Install the (A) flywheel inspection cover and the 5 (B) bolts.





9. With a suitable drain pan properly positioned, remove the plugs and connect the fluid cooler tubes to the CBV.











10. Connect the electrical harness connectors at the (A) vehicle speed sensor (VSS), the (B) digital transmission range (TR) sensor and the (C) solenoid body.





11. Install the (A) heat shield. Tighten the (B) bolts.





12. Install the transmission support crossmember.
1. Install the (A) transmission support crossmember and the (B) nuts onto the (C) retainer and insulator.
2. Raise the transmission, aligning the (A) transmission support crossmember to the (D) frame.
3. Install the (E) stud brackets and the (F) nuts.





13. Remove the (A) High lift Transmission Jack with the (B) E40D Transmission Jack Adapter from the C) transmission.





14. Reinstall the transmission fluid pan-to-case retaining bolts removed to install the jack adapter.
15. Install the starter motor.
16. Install the transmission-mounted parking brake assembly (if so equipped).
17. Install the driveshaft.





18. Install the shift cable.
19. Remove the supports and lower the vehicle.





20. Install and alternately snug, then tighten the transmission-to-engine bolts.








21. Install the (A) fluid filler tube into the (B) short fluid inlet tube. Position the (C) retaining brackets and install the (E) nut and the (F) bolt.

NOTE: Prior to installation, check the condition of the transmission fluid filler tube O-ring. Replace it if damaged.

22. Install the engine cover.
23. Install the air cleaner air intake duct assembly.
24. Connect the battery ground cables.
25. Fill the transmission to the specified level with MERCON(R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent.