Installation
Transmission - 4x2Special Tool:
Special Tool(s)
Material:
Material
1. WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.
NOTE: Rotate the torque converter so that the torque converter paint mark is in the 12 o'clock position.
Install the special tool if not done during assembly.
2. Raise and position the transmission to the back of the engine.
3. Remove the special tool.
4. Position the fuel line bracket in place and install the 6 engine-to-transmission retaining bolts.
^ Tighten to 48 Nm (35 ft. lbs.).
5. Install the 4 torque converter nuts.
^ Tighten to 40 Nm (30 ft. lbs.).
6. Install the starter motor.
^ Tighten to 25 Nm (18 ft. lbs.).
7. Install the ground cable and nut.
^ Tighten to 13 Nm (10 ft. lbs.).
8. Install the lower transmission retaining bolts.
^ Tighten to 48 Nm (35 ft. lbs.).
9. CAUTION: Use care not to bend or force the cooler tubes otherwise damage to the cooler tubes and the transmission can result.
CAUTION: Hold the transmission case fittings with a backup wrench.
Install the transmission fluid cooler tubes.
^ Tighten to 40 Nm (30 ft. lbs.).
10. Position the wire harness and install the retainers.
11. Connect the digital transmission range (TR) sensor electrical connector.
12. Move the rubber boot back over the connector.
13. Connect the LH heated oxygen sensor (HO2S) to the transmission and install the wire harness retainer.
14. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around connector to prevent contamination of the solenoid body connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
^ Tighten to 5 Nm (44 inch lbs.).
15. Connect the LH catalyst monitor connector to the transmission.
16. Connect the RH HO2S to the transmission.
17. Connect the fuel lines and the RH catalyst monitor connector to the bracket.
18. Connect the turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor, and intermediate shaft speed sensor electrical connectors.
19. Install the shift cable and bracket.
^ Tighten to 40 Nm (30 ft. lbs.).
20. NOTE: If the shield is loose on the cable, replace the shield.
Install the cable shield.
21. If removed, install the transmission insulator.
^ Tighten to 90 Nm (66 ft. lbs.).
22. NOTE: RE side shown, LH side similar.
NOTE: This step may require an assistant.
Position the catalytic 3-way converter assembly and loosely install the 4 converter-to-manifold nuts.
23. NOTE: LH side shown, RH side similar.
Connect the 2 HO2S electrical connectors.
24. NOTE: LH side shown, RH side similar.
Connect the 2 catalyst monitor sensor electrical connectors.
25. Position the crossmember in place and loosely install the 2 nuts to hold up the crossmember.
26. Install the 4 RH side crossmember bolts and 1 nut.
^ Tighten to 70 Nm (52 ft. lbs.).
27. Install the 4 LH side crossmember bolts and 1 nut.
^ Tighten to 70 Nm (52 ft. lbs.).
28. Tighten the rear transmission mount nuts.
^ Tighten to 90 Nm (66 ft. lbs.).
29. Remove the transmission Jack from under the transmission.
30. Install the cable bracket and 2 bolts.
^ Tighten to 40 Nm (30 ft. lbs.).
31. Install the RH heat shield and bolts.
^ Tighten to 20 Nm (15 ft. lbs.).
32. Install the LH heat shield bolts.
^ Tighten to 20 Nm (15 ft. lbs.).
33. NOTE: RH shown, LH similar.
Tighten the 4 converter-to-manifold nuts.
^ Tighten to 40 Nm (30 ft. lbs.).
34. Using a new gasket, install the converter-to-muffler pipe and the heat shield. Install the bolts, springs and flag nuts.
^ Tighten to 40 Nm (30 ft. lbs.).
35. CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with threadlock and sealer.
CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in a cross pattern as shown.
With the marks aligned, install the rear driveshaft and bolts.
^ Tighten to 112 Nm (83 ft. lbs.).
36. Use the following guidelines for installing 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.
37. 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 can 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.
38. Position the fan shroud and install the bolts.
39. Carry out the fluid level check.
40. Verify that the shift cable is correctly adjusted.
41. Check the operation of the transmission and inspect for leaks.