Installation

Transmission









Installation

1. If not installed during assembly, install the Torque Converter Retainer.





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





3. Position then raise the transmission into the vehicle.

- WARNING: Secure the torque converter in the transmission during removal or installation. The torque converter is heavy and may result in injury if it falls out of the transmission. Failure to follow this instruction may result in serious personal injury.

While holding the torque converter, carefully tilt the front of the transmission downward.

- NOTICE: Do not allow the torque converter drive flats to disengage from the pump gear, or damage may occur.

While continuing to hold the torque converter, raise the transmission upward.

- NOTICE: Watch for clearance between the transmission and the right side heat shield, as well as other obstructions while raising the transmission, or damage may occur.

While continuing to hold the torque converter raise the transmission positioning the extension housing above the exhaust crossover pipe.

- NOTICE: Watch for clearance between the transmission and the exhaust crossover pipe, or damage may occur.

Tilt the front of the transmission upward until level.





4. Remove the Torque Converter Retainer.





5. NOTICE: 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.

Align the torque converter studs with the mounting holes in the flexplate. Install the transmission to the engine.





6. Install and alternately tighten the torque converter housing-to-engine retaining bolts.
- Tighten to 59 Nm (44 lb-ft).

7. Install 4 new torque converter nuts.
- Tighten to 36 Nm (27 lb-ft).





8. Install the transmission inspection cover.

1. Position the transmission inspection cover.

2. Install the 2 bolts.
- Tighten to 35 Nm (26 lb-ft).

3. Install the bolt for the separator plate.
- Tighten to 35 Nm (26 lb-ft).





9. Install the torque converter access plug.

10. Connect the electrical connectors and install the wire harness on the transmission.

1. Connect the Transmission Range (TR) sensor connector.

2. Connect the Output Shaft Speed (OSS) sensor connector.

3. Install the Turbine Shaft Speed (TSS) sensor connector.





11. Connect the transmission vehicle harness connector.





12. If equipped, install the front A/C deflector assembly with the fasteners.





13. Install the transmission support crossmember.

1. Install the transmission support crossmember onto the transmission retainer and insulator studs. Install the retaining nuts hand-tight.

2. Raise the transmission, aligning the transmission support crossmember to the frame.

3. Install the stud brackets and the crossmember-to-frame retaining nuts.
- Tighten to 81 Nm (60 lb-ft).

4. Tighten the transmission insulator retainer-to-crossmember retaining nuts.
- Tighten to 90 Nm (66 lb-ft).





14. Remove the high-lift transmission jack.





15. Connect the catalyst monitoring sensor harness connectors.





16. Install the exhaust heat shield-to-crossmember retaining bolts.
- Tighten to 15 Nm (133 lb-in).





17. Install the starter motor.

18. NOTE: The output shaft and the driveshaft are a balanced assembly.

Install the driveshaft.

- Align the index marks and position the driveshaft on the transmission.

- Position the driveshaft to the rear differential.





19. NOTE: To maintain initial driveshaft balance, align the index marks made during removal.

Install the driveshaft bolts and the driveshaft.

- Tighten to 103 Nm (76 lb-ft).





20. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.

Install the selector lever cable and selector lever cable bracket.

1. Install the selector lever cable bracket bolts.
- Tighten to 25 Nm (18 lb-ft).

2. Connect the selector lever cable to the manual lever.





21. NOTE: Prior to installation, check the condition of the transmission fluid filler tube O-ring. If damaged, install a new O-ring.

Install the transmission fluid filler tube into the transmission. Position the retaining brackets and install the bolt.

- Tighten to 10 Nm (89 lb-in).





22. Install the transmission fluid filler tube nut.
- Tighten to 10 Nm (89 lb-in) for 4.6L.

- Tighten to 28 Nm (21 lb-ft) for 5.4L.





23. With a drain pan correctly positioned, remove the plugs and connect the transmission fluid cooler tubes.
- Tighten to 27 Nm (20 lb-ft).





24. Install the transmission bolts and position fuel line in place.
- Tighten to 59 Nm (44 lb-ft).





25. Connect the electrical harness connectors.





26. 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 transmission fluid filter, install a new in-line transmission fluid filter.

- If the transmission was overhauled and the vehicle was not equipped with an in-line transmission fluid filter, install a new in-line transmission fluid filter kit.

- If the transmission is being installed for a non-internal repair, do not install an in-line transmission filter or filter kit.

- If installing a new or a Ford authorized remanufactured transmission, install a new in-line transmission fluid filter.

Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit. For additional information, refer to Transmission Fluid In-Line Filter Transmission Fluid In-Line Filter.

27. Install the engine cover.

28. Install the Air Cleaner (ACL) air intake duct assembly.

29. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.

Connect the battery.

30. Fill the transmission to the specified level with transmission fluid.