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Installation




Transmission - Gasoline Engines









Installation

All vehicles

NOTICE: 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.

NOTICE: Prior to installation of a new or overhauled transmission, the transmission fluid cooler tubes must be cleaned. Otherwise transmission failure can occur.

1. NOTICE: Prior to installation of the transmission, the torque converter pilot hub must be lubricated or damage to the torque converter or the engine crankshaft can occur.

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





2. Rotate the torque converter so the green or orange paint daub on the converter is in the 12 o'clock position.

3. If the Torque Converter Retainer has not been installed during the assembly of the transmission, install the Torque Converter Retainer 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 Torque Converter Retainer.





4. Install a new transmission fluid filler tube O-ring.





5. Position the transmission in place. While raising the transmission up into the engine compartment, align the transmission fluid filler tube with the stub tube on the transmission using the transmission 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 lb-ft).





7. Using a suitable tool, rotate the crankshaft pulley to gain access to the torque converter-to-flexplate nuts.





8. Install the 6 new torque converter-to-flexplate nuts.
- Tighten to 48 Nm (35 lb-ft).





9. Install the cylinder block opening cover.





10. Position the steering damper and install the steering damper-to-frame bolt and nut.
- Tighten to 103 Nm (76 lb-ft).





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

12. If equipped with dual generators, rotate the tensioner and install the outer accessory drive belt onto the crankshaft pulley.





13. Install the front transmission fluid cooler tube.
- Tighten to 40 Nm (30 lb-ft).





14. Install the rear transmission fluid cooler tube.
- Tighten to 40 Nm (30 lb-ft).





15. Install the flexplate inspection cover.

1. Position the flexplate inspection cover.

2. Install the flexplate inspection cover bolts.
- Tighten to 34 Nm (25 lb-ft).





16. Install the transmission insulator and retainer extension housing bolts.
- Tighten to 103 Nm (76 lb-ft).





17. If required, install a new transmission insulator and retainer stud.
- Tighten to 75 Nm (55 lb-ft).

18. Install the transmission support crossmember.

19. Connect the fuel line bracket and install the fuel line bracket nut.
- Tighten to 12 Nm (106 lb-in).





20. NOTE: RH shown, LH similar.

Connect the RH and LH wiring harness to the side of the transmission.





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





22. Connect the Turbine Shaft Speed (TSS)/intermediate shaft speed sensor.





23. Connect the transmission vehicle harness connector.
- Tighten to 5 Nm (44 lb-in).





24. 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.

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

Connect the selector lever cable.

1. Install the selector lever cable housing bracket and selector lever cable housing bracket bolts.
- Tighten to 48 Nm (35 lb-ft).

2. Install the selector lever cable to the manual control lever.





Four-Wheel Drive (4WD) vehicles

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

Rear Wheel Drive (RWD) vehicles

26. Install the rear driveshaft. For additional information, refer to Drive/Propeller Shafts, Bearings and Joints.

All vehicles

27. Install the exhaust pipe between the exhaust manifold and the exhaust flange. For additional information, refer to Exhaust System &/or Catalytic Converter.

28. Connect the battery. For additional information, refer to Battery.

29. NOTE: 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 the in-line transmission fluid filter, install a new in-line transmission fluid filter.
- If the transmission is being installed for a non-internal repair, do not install an in-line transmission fluid filter or transmission fluid 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.

30. With the installation of an overhauled or remanufactured transmission, the transmission fluid cooler tubes must be cleaned and back-flushed, and then the transmission fluid flow verified in order to prevent repeat repairs. For additional information, refer to Transmission Fluid Cooler Backflushing and Cleaning Procedures and Transmission Fluid Cooler TorqShift.

31. Adjust the selector lever cable. Verify that the vehicle starts in PARK and NEUTRAL and the reverse lamps illuminate in REVERSE. For additional information, refer to Automatic Transmission/Transaxle.

32. 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 transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved (transmission fluid should be in the hot range cross-hatched area of the transmission fluid level indicator).

33. 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.

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