Removal

Special Tools:

Removal
All vehicles





1. Place the transmission range selector lever in the NEUTRAL position.

2. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If a concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis.

The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition.
Disconnect the battery ground cable.
3. Raise the vehicle on a hoist.
Excursion 7.3L diesel





4. Remove the belly pan.
1. Remove the six retaining bolts.
2. Remove the belly pan.
All vehicles
5. If transmission disassembly is required, drain the transmission fluid.





6. Remove the transmission oil filler tube nut.





7. Remove the oil filler tube.





8. Position a suitable drain pan and disconnect the transmission fluid cooler tubes at the cooler bypass valve.
9. Remove the driveshaft.
4x4 vehicles
10. Remove the transfer case assembly.
Super Duty/MOTORHOME vehicles
11. If equipped, remove the transmission mounted parking brake assembly.
All vehicles

12. Note: If the vehicle is equipped with a power take-off unit all or part of the PTO unit will need to be removed.





Disconnect the shift cable from the transmission.
1. Disconnect the shift cable from the manual lever.
2. Disconnect the cable housing from the bracket and position aside.





13. Disconnect the digital transmission ranger (TR) sensor connector.





14. Disconnect the solenoid body connector.





15. Disconnect the Turbine Shaft Speed (TSS) sensor and the Output Shaft Speed (OSS) sensor.
16. Remove the starter motor.





17. Remove the cylinder block opening cover.





18. Disconnect the torque converter.
- Rotate the crankshaft to position the torque converter-to-flywheel nut in the center of the cylinder block opening.
- Remove and discard the torque converter-to-flexplate nuts.





19. Remove the flexplate inspection cover.
1. Remove the bolts.
2. Remove the inspection plate.
7.3L diesel vehicles
20. Remove the starter.





21. Remove the inspection cover.
1. Remove the bolts.
2. Remove the cover.





22. Remove and discard the torque converter-to-flexplate nuts.
All vehicles

23. CAUTION: Make sure any securing straps or the transmission jack adapter do not touch the Cooler Bypass Valve (CBV). Do not use the CBV as a handle. Damage to the CBV may cause a leak and/or failure to the transmission assembly.





Install the High Lift Transmission Jack with the E40D Transmission Jack Adapter to the transmission.





24. Remove the bolts.





25. Remove the bolts.





26. Remove the crossmember bolts and crossmember.
27. Remove the exhaust.





28. Remove the transmission.
1. Remove the six transmission-to-engine (diesel) mounting bolts or seven transmission-to-engine (gasoline) mounting bolts.
2. Gently rock the transmission side-to-side to disengage it from the locator dowels.
3. Move the transmission and the transmission jack rearward to clear the engine flexplate.
29. Install Torque Converter Holding Tool.

30. CAUTION:
- Use care while removing the transmission to avoid obstructions.
- Do not use the cooler bypass valve as a handle. Damage to the cooler bypass valve assembly may occur or damage to the case may result.
- 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.





Wiggle the transmission back and forth and lower the transmission out of the vehicle.
31. Remove the Torque Converter Holding Tool.

32. WARNING: The torque converter is very heavy.

Note: Fluid loss will occur when the torque converter is removed.





If required. remove the torque converter from the transmission.
1. Install the Torque Converter Handles and position them at 6 o'clock and 12 o'clock.
2. Carefully remove the (A) torque converter from the (B) transmission by pulling evenly on the handles.