Installation

INSTALLATION
Transmission
4x4 vehicles





1. Install the vent tube assembly.

All vehicles

2. WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions may result in personal injury.

Raise and position the transmission.





3. Remove the special tool.

4.0L SOHC engine





4. NOTE: Align the flexplate to the converter marks made at removal. Install the transmission to engine screws.

1. Install 2 M10 x 40 mm (1.6 inch) screws.
2. Install 4 M10 x 50 mm (2 inch) screws.
3. Install 2 M10 x 75 mm (3 inch) screws.

2.3L and 3.0L engines





5. NOTE: Align the flexplate to the converter marks made at removal. Install the screws.

1. Install 1 M10 x 40 mm (1.6 inch) screw.
2. Install 4 M10 x 50 mm (2 inch) screws.
3. Install 2 M10 x 75 mm (3 inch) screws.





6. Install the upper fluid filler tube and bracket screw.
1. Install the upper filler tube.
2. Install the M10 x 40 mm (1.6 inch) bracket screw.

2.3L engine





7. Install the lower transmission to engine screws.





8. Install the HO2S connector bracket.





9. Install the rear engine cover plate.

4x4 vehicles

10. Install the transfer case.

All vehicles





11. Install the screws.
1. Install the exhaust bracket.
2. Install the screws.

4x2 vehicles





12. Install the crossmember.
1. Position the crossmember.
2. Install the eight bolts (four each side).

4x4 vehicles





13. Install the crossmember.
1. Position the crossmember.
2. Install the six crossmember bolts (three each side).

All vehicles





14. Install the transmission mount into the crossmember and tighten the nuts.
15. Remove the High-Lift Transmission Jack.





16. CAUTION: Care should be taken not to bend or damage the cooler lines.

Hold the case fitting and install the transmission cooler lines.





17. Install the four nuts.
^ Rotate the crankshaft as needed to gain access to all the nuts.

2.3L vehicles





18. Install the four nuts.
^ Rotate the crankshaft as needed to gain access to all the nuts.

All vehicles

19. Install the starter motor.
20. Install the catalytic converter assembly.





21. Connect the transmission wiring harness.
1. Connect the transmission connector.
2. Connect the intermediate shaft speed (ISS) sensor.
3. Connect the digital transmission range (TR) sensor connector.
4. Connect the output shaft speed (OSS) sensor





22. Install the shift cable.
1. Connect the shift cable to manual control lever.
2. Connect the shift cable to the bracket.





23. NOTE: Align the driveshaft yoke and the axle shaft marks made at removal to maintain driveline balance.

Install the rear driveshaft.
1. Position the driveshaft.
2. Install the four bolts.
24. Lower the vehicle.

4.0L SOHC vehicles





25. Install the transmission fill tube and indicator as an assembly.

All vehicles

26. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts (either soft or firm) and this is a temporary condition that will eventually return to normal operating condition.

Connect the battery ground cable.
27. Fill the transmission with fluid and inspect for correct operation.
^ Use Motorcraft MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford MERCON V specification.
28. Verify that the shift cable is correctly adjusted.