Installation

Special Tools:

Installation
All vehicles

1. CAUTION:
- Prior to the installation of the transmission the fluid, cooler lines and the cooler bypass valve will need to be cleaned. Transmission failure could occur if not cleaned.
- The transmission Oil-To-Air
(0TA) cooler will need to be replaced if the transmission was overhauled or exchanged due to a failure of the transmission. Transmission failure could occur.

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

2. CAUTION: Prior to the installation of the assembly, the torque converter pilot hub must be properly lubricated or damage to the torque converter or the engine crankshaft could occur.





Lubricate the torque converter pilot hub.
- Use Ford Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-B.
3. If not installed during assembly, install the Torque Converter Holding Tool.

4. CAUTION:
- 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.
- Be careful not to raise the transmission up too far. The sensors may make contact with the underbody of the vehicle and cause damage to the sensors. Sensor failure or leakage may occur.





Position the transmission.
- Raise the rear of the transmission to clear the crossmember.
5. Remove the Torque Converter Holding Tool.





6. Connect the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor.

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





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





8. Install seven transmission-to-engine bolts.





9. Install the new torque converter-to-flexplate nuts.
- Rotate flexplate to gain access to the nuts.





10. Install the flexplate inspection cover bolts.





11. Install the cylinder block opening cover.
Diesel vehicles





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





13. Install six transmission-to-engine bolts.





14. Install new torque converter retaining nuts.





15. Install the flexplate inspection cover bolts.
1. Install the flexplate inspection cover.
2. Install the flexplate inspection cover bolts.
16. Install the starter motor.
All vehicles
17. Install the starter.
18. Install the exhaust.





19. Install the crossmember and the crossmember bolts.





20. Install the bolts.





21. Install the bolts.





22. Remove the High Lift Transmission Jack.
4x4 vehicles
23. Install the transfer case.
Super Duty/MOTORHOME vehicles
24. If equipped install the transmission mounted parking brake assembly.
All vehicles





25. Connect the solenoid pack electrical connector.





26. Connect the digital Transmission (TR) sensor connector.





27. Connect the shift cable.
1. Install the cable housing to the bracket.
2. Install the shift cable to the manual lever.
28. If equipped, install the power take-off unit.

29. Note: If the transmission fluid cooler tubes or the cooler bypass valve have not been flushed it would be necessary to do so at this time. Replace the oil-to-air cooler.





Install the transmission fluid cooler tubes to the cooler bypass valve.





30. Install the transmission fluid filler tube into the transmission stub tube.





31. Install the transmission fluid filler tube bolt.
Excursion 7.3L diesel





32. Install the belly pan.
1. Install the belly pan.
2. Install the six retaining bolts.
All vehicles
33. Lower the vehicle.

34. 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.
Connect the battery ground cable.
35. Fill to proper level with MERCON V(R) Multi-Purpose (ATF) Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON V(R).