Installation
Transmission-Four Wheel Drive (4WD)Special Tool(s):
Material:
Installation
1. Install the special tool if not done during the assembly process.
2. Position the vent tube on the top of the transmission.
3. CAUTION: To position the transmission in the vehicle, put the transmission into a nose-down position to get the tail shaft over the exhaust system. The converter housing is piloted into position by dowels in the rear of the engine block. The torque converter must rest squarely against the flexplate. This indicates that the converter pilot is not binding in the engine crankshaft.
Position and secure the transmission on a suitable high-lift transmission jack. Raise and position the transmission into the vehicle. Once the transmission is in position, place the transmission in a horizontal position.
4. NOTE: Do not remove the special tool until the transmission is in a horizontal position.
Remove the special tool.
5. NOTE: Make sure that the torque converter is fully seated in the transmission before aligning the transmission to the engine.
With the transmission in a horizontal position move it toward the engine. Align the orange balancing marks between the torque converter and the flexplate bolt holes.
6. NOTE: Install the transmission retaining bolts in their correct locations made during removal.
Install the selector lever cable bracket and the LH transmission retaining bolts.
^ Tighten to 48 Nm (35 ft. lbs.).
7. NOTE: Install the transmission retaining bolts in their correct locations made during removal.
Position the vent tube in its correct location and install the RH transmission retaining bolts.
^ Tighten to 48 Nm (35 ft. lbs.).
8. NOTE: It may be necessary to disconnect the rubber vent hose in order to route the wire harness under the vent hose.
Route the harness under the vent hose, connect the solenoid body connector and connect the harness retainer to the transmission.
^ Tighten to 5 Nm (44 inch lbs.).
9. Connect the transmission electrical connectors.
1 Connect the digital transmission range (TR) sensor.
2 Connect the output shaft speed (OSS) sensor.
3 Connect the turbine shaft speed (TSS) sensor.
10. Install the transmission insulator and bolts.
^ Tighten to 80 Nm (59 ft. lbs.).
11. Position the rear crossmember in place and install the transmission insulator nuts.
^ Tighten to 103 Nm (76 ft. lbs.).
12. Position the rear crossmember in place and install the bolts.
^ Tighten to 115 Nm (85 ft. lbs.).
13. Remove the transmission jack.
14. Install the RH exhaust shield bolt.
^ Tighten to 15 Nm (11 ft. lbs.).
15. Install the LH exhaust shield bolt.
^ Tighten to 15 Nm (11 ft. lbs.).
16. Install the bolts retaining the exhaust hanger to the crossmember.
^ Tighten to 40 Nm (30 ft. lbs.).
17. Position the transmission fluid fill tube into the transmission and install the retaining bolt on the RH cylinder head.
^ Tighten to 12 Nm (9 ft. lbs.).
18. Connect the transmission fluid cooler tubes.
^ Tighten to 27 Nm (20 ft. lbs.).
19. Install the starter motor and install 3 bolts.
^ Tighten to 26 Nm (19 ft. lbs.).
20. Install the starter motor electrical connectors and the ground wire.
1 Connect the large battery cable.
^ Tighten to 12 Nm (9 ft. lbs.).
2 Connect the small battery cable.
^ Tighten to 6 Nm (53 inch lbs.).
3 Connect the battery ground cable.
^ Tighten to 23 Nm (17 ft. lbs.).
21. Install the plastic starter motor electrical connector cap.
22. Install 4 new torque converter nuts.
^ Rotate the crankshaft to access all the torque converter nuts.
- Tighten to 36 Nm (27 ft. lbs.).
23. Install the rubber access plug.
24. Install the flexplate inspection cover
^ Tighten to 34 Nm (25 ft. lbs.).
25. Install the selector lever cable bracket.
^ Tighten to 25 Nm (18 ft. lbs.).
26. CAUTION: Failure to route the selector lever cable in the routing clip can allow the cable to rest on exhaust components, causing damage to the cable.
Route the selector lever cable in the routing clip.
27. Install the HO2S connector onto the selector lever bracket.
28. Connect the HO2S electrical connector.
29. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed.
Connect the selector lever cable end onto the manual control lever.
30. Install the transfer case.
31. 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.
32. Fill to correct level with clean automatic transmission fluid.