Transmission - Installation

Transmission - Four Wheel Drive (4WD)









Installation

1. Install the Torque Converter Retainer if not done during the assembly process.





2. Position the vent tube on the top of the transmission.





3. Position and secure the transmission on a suitable high-lift transmission jack. Raise and position the transmission into the vehicle.





4. NOTICE: Prior to installation of the transmission, the torque converter pilot hub must be lubricated with multi-purpose grease or damage to the torque converter or the engine crankshaft can occur.

Lubricate the torque converter pilot hub with multi-purpose grease.





5. NOTE: Do not remove the Torque Converter Retainer until the transmission is in position.

Remove the Torque Converter Retainer.





6. 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 balance marks between the torque converter and the flexplate bolt holes.

7. NOTE: Install the transmission retaining bolts in their original positions as noted during removal.

Install the fuel line bracket and the LH transmission case retaining bolts.

- Tighten to 48 Nm (35 lb-ft).





8. NOTE: Install the transmission retaining bolts in their original positions as noted during removal.

Position the vent tube in its correct location and install the RH transmission case retaining bolts.

- Tighten to 48 Nm (35 lb-ft).





9. NOTE: It may be necessary to disconnect the rubber vent hose in order to route the wire harness under the vent hose.

Connect the transmission vehicle harness connector and connect the harness clip to the top of the transmission.





10. Connect the transmission electrical connectors.

1. Connect the Transmission Range (TR) sensor.

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

3. Connect the Turbine Shaft Speed (TSS) sensor.





11. Position the transmission fluid fill tube into the transmission and install the retaining bolt on the RH cylinder head.
- Tighten to 12 Nm (106 lb-in).





12. Install the starter motor. For additional information, refer to Starting System.

13. Connect the transmission fluid cooler tube nuts.
- Tighten to 27 Nm (20 lb-ft).





14. Install the transmission fluid cooler tube bracket nut to the transmission case stud bolt.
- Tighten to 27 Nm (20 lb-ft).





15. Install 4 new torque converter nuts.
- Rotate the crankshaft to access all the torque converter nuts.
- Tighten to 36 Nm (27 lb-ft).





16. Install the rubber access plug.





17. 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).





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





19. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket.

NOTE: When installing the selector lever cable end, pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed onto the manual control lever.

Connect the selector lever cable end onto the manual control lever.





20. Install the fuel line bracket and bolt.
- Tighten to 25 Nm (18 lb-ft).





21. NOTICE: Prior to Installation, Inspect the Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS) wiring harness for damage.

Position the dual converter Y-pipe in place and install the 2 dual converter Y-pipe exhaust bolts.

- Tighten to 40 Nm (30 lb-ft).





22. NOTE: LH shown, RH similar.

Install the RH and LH exhaust flange nuts to the exhaust manifold.

- Tighten to 40 Nm (30 lb-ft).





23. NOTE: LH shown.

Connect the LH and RH HO2S and the LH and RH CMS electrical connectors. Install the wiring harness at the top RH side of the transmission.





24. Position a jackstand under the transmission, and remove the high-lift transmission jack for transfer case installation.





25. Install the transfer case. For additional information, refer to Transfer Case.

26. Use the following guidelines for the transmission fluid in-line filter:
- If the transmission was overhauled and the vehicle was equipped with a transmission fluid in-line filter, install a new transmission fluid in-line filter.

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

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

- If installing a Ford-authorized remanufactured transmission, install a transmission fluid in-line filter.
Prior to lowering the vehicle, install a new transmission fluid in-line filter or a filter kit. For additional information, refer to Transmission Filter - In Line Transmission Filter - In Line.

27. Connect the battery ground cable. For additional information, refer to Battery.

28. Verify that the selector lever cable is correctly adjusted.

29. Fill the transmission with automatic transmission fluid.

30. Install the transmission fluid level indicator.