Transmission Installation

INSTALLATION
Transmission





Special Tool(s)





Material

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 transmission, the torque converter pilot hub must be 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.

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





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.





13. Connect the solenoid pack electrical connector.





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





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





16. NOTE: If the vehicle is equipped with a Power Take-Off (PTO)) 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.





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

4x4 vehicles





18. Support the extension housing with a Jack stand and remove the transmission Jack.
19. Install the transfer case.

4x2 vehicles





20. Install the transmission mount.





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





22. Install the crossmember bolts.





23. Install the crossmember bolts.





24. Reconnect the wire harness to the frame.
25. Remove the transmission Jack.





26. Tighten the nuts.
27. Install the rear driveshaft.
28. 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 new or 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.

29. 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.
30. Fill the transmission to the correct level with clean automatic transmission fluid.