Installation
Transmission - Diesel EnginesSpecial Tool(s):
Material:
Installation
All vehicles
CAUTION: Install a new oil-to-air (OTA) cooler as part of a transmission overhaul, or when installing a remanufactured transmission due to major metallic failure, multiple clutches or clutch plate failures or sufficient component wear, which results in metallic contamination.
CAUTION: Prior to installation of a new or overhauled transmission, the fluid cooler lines must be cleaned. Otherwise transmission failure can occur.
1. CAUTION: Prior to installation of a new or overhauled transmission, a new transmission fluid cooler remote filter element must be installed. Otherwise transmission failure can occur.
If necessary, install a new transmission fluid cooler remote filter element.
2. CAUTION: Prior to 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.
3. Rotate the torque converter so the green or orange paint daub on the converter is in the 12 o'clock position.
4. If the special tool has not been installed during the assembly of the transmission, install the special tool to hold the torque converter in place while moving and positioning the transmission in place. Once the transmission is in place, prior to bolting it to the engine, remove the special tool.
5. Position the transmission in place. While raising the transmission up into the engine compartment, align the fluid filler tube with the stub tube on the transmission using the fluid level indicator as a guide.
While installing the transmission to the engine, align the torque converter studs with the mounting holes in the flexplate.
6. Install the 9 transmission-to-engine bolts.
^ Tighten to 47 Nm (35 ft. lbs.).
7. Using a suitable strap wrench to rotate the crankshaft and pulley, install the 6 new torque converter-to-flexplate nuts.
^ Tighten to 48 Nm (35 ft. lbs.).
8. Install the cylinder block opening cover.
9. Install the flexplate inspection cover.
1 Position the flexplate inspection cover.
2 Install the bolts.
^ Tighten to 34 Nm (25 ft. lbs.).
10. If equipped with dual generators, rotate the tensioner and install the outer accessory drive belt onto the crankshaft pulley.
11. Install the front transmission fluid cooler tube.
^ Tighten to 40 Nm (30 ft. lbs.).
12. Install the rear transmission fluid cooler tube.
^ Tighten to 40 Nm (30 ft. lbs.).
Four wheel drive (4WD) vehicles
13. Support the extension housing with a jack stand and remove the transmission jack.
Rear wheel drive (RWD) vehicles
14. Install the transmission mount bolts.
^ Tighten to 94 Nm (69 ft. lbs.).
15. Position the crossmember to the transmission mount and loosely install the nut.
16. Install the LH crossmember bolts.
^ Tighten to 81 Nm (60 ft. lbs.).
17. Install the RH crossmember bolts.
^ Tighten to 81 Nm (60 ft. lbs.).
18. Install the bracket and loosely install the bolts.
1 Install the bracket.
2 Loosely install the bolts.
19. Tighten the RH crossmember bolts.
^ Tighten to 81 Nm (60 ft. lbs.).
20. Tighten the rear insulator nuts.
^ Tighten to 103 Nm (76 ft. lbs.).
All vehicles
21. Connect the fuel line bracket.
^ Tighten to 12 Nm (9 ft. lbs.).
22. NOTE: RH shown, LH similar.
Connect the RH and LH wiring harness to the side of the transmission.
23. Connect the output shaft speed (OSS) sensor electrical connector.
24. Connect the intermediate shaft and turbine shaft combination speed sensor electrical connector.
25. Connect the solenoid body electrical connector.
^ Tighten to 5 Nm (44 inch lbs.).
26. 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 selector lever cable.
1 Install the cable housing bracket.
^ Tighten to 25 Nm (18 ft. lbs.).
2 Install the selector lever cable to the manual lever.
RWD vehicles
27. Reconnect the wire harness to the frame.
4WD vehicles
28. If equipped, install the transfer case.
RWD vehicles
29. Install the rear driveshaft.
All vehicles
30. Connect the battery. For additional information, refer to Battery.
31. NOTE: Use these guidelines for the in-line transmission 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 the in-line fluid filter, install a new in-line fluid filter.
^ 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 an in-line transmission fluid filter.
Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit.
32. Adjust the shift linkage. Verify that the vehicle starts in PARK and NEUTRAL and the reverse lamps illuminate in REVERSE.
33. With the engine running and the transmission at normal operating temperature 66 - 77°C (150 - 170°F), check and adjust the transmission fluid level, and check for any leaks. If fluid is needed, add fluid in increments of 0.24L (0.5 pint) until the correct level is achieved (fluid should be in the hot range cross-hatched area of the fluid level indicator).
34. For vehicles equipped with a PTO assembly, prior to installing the transmission, the PTO assembly must be flushed and cleaned to remove any foreign material. Failure to remove foreign material from the PTO assembly may result in subsequent transmission concerns.