Operation CHARM: Car repair manuals for everyone.
Home >> Ford Truck >> 2003 >> F 550 4WD Super Duty V8-6.0L DSL Turbo VIN P >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Automatic Transmission - 4R100 >> Installation

Installation

Transmission





Special Tool(s)

Installation

All vehicles

1. CAUTION: Prior to the installation of the transmission, the fluid, cooler lines and the cooler bypass valve must be cleaned. Transmission failure can occur if this procedure is not followed.

CAUTION: A new transmission Oil-To-Air (OTA) cooler must be installed if the transmission was overhauled or exchanged due to a failure of the transmission. Transmission failure can occur if this procedure is not followed.

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





Vehicles equipped with a transmission-mounted parking brake
2. If removed, install the parking brake
1 Position the parking brake assembly with a new gasket on the transmission extension housing
2 Install six new bolts





All vehicles

3. CAUTION: Prior to the installation of the assembly, the torque converter pilot hub must be correctly lubricated or damage to the torque converter or the engine crankshaft can occur.

Lubricate the torque converter pilot hub with multi-purpose grease.





4. Raise the transmission into place





5. CAUTION: Do not use the cooler bypass valve as a handle. Damage to the cooler bypass valve assembly can occur or damage to the case can result.

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

NOTE: While raising the transmission up into the engine compartment, make sure to align the fluid filler tube with the stub tube on the transmission, using the dipstick as a guide.

Position the transmission.





6. Remove the special tool.





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 crankshaft.

NOTE: Gasoline engine shown, diesel engine similar.

While installing the transmission to the engine, align the torque converter studs with the mounting holes in the flexplate.





Gasoline engines
8. Install seven transmission-to-engine bolts.





9. Install the new torque converter-to-flexplate nuts.
^ 5.4L engines have four torque converter nuts.
^ 6.8L engines have six torque converter nuts.





10. Install the cylinder block opening cover.





11. Install the flexplate inspection cover and bolts,
12. Install the starter motor.





Diesel engines
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. Connect the solenoid pack electrical connector.





18. Connect the Digital Transmission (TR) sensor connector.





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





20. NOTE: If the vehicle is equipped with a power take-off unit, all or part of the PTO unit will need to be installed.

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





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





Vehicle equipped with a transmission-mounted parking brake
22. Position the front parking brake cable and conduit, and press the retainer into the cable bracket until it snaps into place.





23. Set the adjusting clevis.
1 Loosen the jam nut several turns.
2 Position the parking brake lever in the applied position.
3 Tighten or loosen the adjusting clevis until the adjusting clevis hole lines up with the parking brake lever hole, then loosen the adjusting clevis to the specification.





24. Install the pins, and tighten the jam nut.
1 Install the clevis pin through the adjusting clevis and the parking brake lever.
2 Install the locking pin in the clevis pin.
3 Tighten the jam nut.





25. Install the parking brake lever return spring.





4x4 vehicles
26. Support the extension housing with a jack stand and remove the transmission jack.
27. Install the transfer case.





4x2 vehicles
28. Install the transmission mount.





29. Position the crossmember to the transmission mount and loosely install the nuts.





4x2 Excursion
30. Install the crossmember bolls.





31. Install the crossmember bolts.





32. Reconnect the wire harness to the frame.





INSTALLATION

F-Super Duty vehicles

33. Install the crossmember bolts.





34. Install the nuts.

4x2 vehicles
35. Remove the transmission jack.





36. Tighten the nuts.
37. Install the rear driveshaft.





38. Use the following guidelines for the in-line transmission fluid filter:
^ If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a new in-line fluid filter.
^ If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter, install a new in-line fluid filter kit.
^ If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter kit.
^ If installing a Ford-authorized remanufactured transmission, install the in-line transmission fluid filter that is supplied.
Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit.

39. Lower the vehicle.

40. 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 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.
41. Fill to correct level with clean automatic transmission fluid.
pro multis · About Operation CHARM