Installation

Transmission

Special Tool(s)

All vehicles

1. WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.

If removed, install the transfer case to the back of the transmission, install the bracket and connect the vent hose.

2. Remove the special tool.

3. WARNING: Make sure that the transmission and transfer case assembly are secured to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.

Raise and position the transmission and transfer case to the back of the engine.

4.6L engine

4. NOTE: Align the flexplate-to-converter marks made during the removal procedure.

Install the seven engine-to-transmission retaining bolts.

5. Install the four torque converter nuts.

6. Install the access cover.

7. Install the flexplate cover.

8. Install the starter.

9. Install the starter motor electrical connectors.

10. Install the starter motor electrical connector cover.

11. NOTE: The RH side is shown, the LH side is similar.

Install the front crossmember and the four bolts (two on each side).

4.0L engine

12. NOTE: Align the flexplate-to-converter marks made during the removal procedure.

Position the fuel line bracket in place and install the six engine-to-transmission retaining bolts.

13. Install the four torque converter nuts.

14. Install the starter motor.

15. Install the lower transmission retaining bolts.

All vehicles
16. Install jackstand under the transfer case.
17. Remove the transmission jack from under the transmission.

18. CAUTION: Use care not to bend or force the cooler tubes otherwise damage to the cooler tubes and the transmission can result.

Install the transmission fluid cooler tubes.

19. Connect the digital Transmission Range (TR) sensor connector.

20. Move the rubber boot back over the connector.

21. Connect the LH Heated Oxygen Sensor (H02S) to the transmission and install the wire harness retainer.

22. Position the wire harness and install the retainers.

23. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification.

NOTE: Always install new O-ring seals on the vehicle harness connector.

NOTE: Clean the area around connector to prevent contamination of the solenoid body connector.

NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.

Install and lubricate new O-ring seals on the transmission connector and connect the connector.

24. Connect the LH catalyst monitor connector to the transmission.

25. Connect the RH Heated Oxygen Sensor (H02S) to the transmission.

26. Connect the fuel lines and the RH catalyst monitor connector to the bracket.

27. Connect the Turbine Shaft Speed (TSS) sensor, Output Shaft Speed (OSS) sensor, and Intermediate Shaft Speed (ISS) sensor electrical connectors.

28. NOTE: This step may require an assistant.

Position the catalytic converter assembly with heat shield and loosely install the four converter-to-manifold nuts.

29. Install the rear transmission mount bolts.

30. NOTE: The LH side is shown, the RH side is similar.

Connect the two heated oxygen sensor electrical connectors.

31. Connect the two catalyst monitor sensor electrical connectors.

32. Position the crossmember in place and loosely install the two nuts to hold up the crossmember.

33. Install the RH side crossmember bolts.

34. Install the LH side crossmember bolts.

35. Remove the jackstand.

36. NOTE: The RH side is shown, LH side is similar.

Install the two upper crossmember bolts (two on each side).

37. Tighten the rear transmission mount nuts.

38. Install the RH heat shield and bolts.

39. Install the LH heat shield bolts.

40. Install the plastic shield on the right side of the crossmember near the fuel tank.

41. Tighten the four converter-to-manifold nuts.

42. Using a new gasket, install the converter-to-muffler pipe and the heat shield. Install the bolts, springs and flag nuts.

43. If equipped, connect the shift motor electrical connector.

44. CAUTION: The can (domed CV joint housing cover) is pressed into the CV joint housing at the factory. When housed correctly, the can will appear as shown in the cut-away illustration, top box. Do not reseat the can in the CV joint housing if the can's flange is above the CV joint housings shown in the cut-away illustration, bottom box. Install a new driveshaft.

Verify that the can flange is housed correctly in the CV joint housing as shown in the cut-away illustration, top box. Install a new driveshaft if the can flange is not housed correctly.

45. CAUTION: Always connect the front driveshaft to the axle first. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.

NOTE: Align the index marks.

Install the driveshaft.

46. CAUTION: Tighten the bolts evenly in a cross pattern or damage will occur to the CV joint.

NOTE: Install new washers and bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.

Install the new washers and bolts. Tighten the bolts evenly in a cross pattern as shown.

47. Verify that the CV joint has seated squarely in the transfer case flange.
^ Check that the space between the end of the CV joint cap and the end of the transfer case flange is equal from the top to the bottom of the two components.
^ Rotate the driveshaft 1/4 turn.
^ Check that the space between the end of the CV joint cap and the end of the transfer case flange is equal from the top to the bottom of the two components.
^ Repeat this procedure several times.
^ If the space is not equal at any point in the attachment, remove and reinstall the driveshaft.

48. NOTE: Install new universal joint retainers and bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.

Install the new universal joint retainer and bolts.

49. CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5.

CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in a cross pattern as shown.

Install the rear driveshaft and the eight bolts.

50. Install the shift cable and bracket.

51. NOTE: If the vehicle was not equipped with a fluid filter, install a fluid filter kit and follow the instructions supplied in the kit. If the vehicle was equipped with a fluid filter, install a new filter.

Install a new in-line transmission fluid filter kit or filter.

All vehicles
52. Lower the vehicle.

4.0L engine
53. Remove the engine lifting hook.

54. Remove the special tools.

55. Remove the engine lifting hook from the cylinder head.
56. Install the exhaust manifold to Exhaust Gas Recirculation (EGR) valve tube.

4.6L engine
57. Remove the special tools.

58. Remove the special tool,

59. Install the bracket and the battery ground cable.

60. Install the appearance cover.

All vehicles
61. Install the upper fan shroud.
1 Position the fan shroud.
2 Install the two retainers.
3 If equipped, connect the A/C line.

62. Install the radiator appearance cover.

63. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they can experience slightly different upshifts (either soft or firm) and that this is a temporary condition and will eventually return to normal operating condition.

Connect the battery ground cable.
64. Carry out the fluid level check.
65. Verify that the shift cable is correctly adjusted.
66. Check the operation of the transmission and inspect for leaks.