Installation

Transmission-4x4





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.
^ Tighten to 41 Nm (30 ft. lbs.).





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.

NOTE: Rotate the torque converter so that the torque converter paint mark is in the 12 o'clock position.

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

4.6L engine





4. Install the 7 engine-to-transmission retaining bolts.
^ Tighten to 48 Nm (35 ft. lbs.).





5. Install the 4 torque converter nuts.
^ Tighten to 35 Nm (26 ft. lbs.).





6. Install the access cover.





7. Install the flexplate cover.
^ Tighten to 34 Nm (25 ft. lbs.).





8. Install the starter.
^ Tighten to 24 Nm (18 ft. lbs.).





9. Install the starter motor electrical connectors.
^ Tighten the cable to 13 Nm (10 ft. lbs.).
^ Tighten the wire to 6 Nm (53 inch lbs.).





10. Install the starter motor electrical connector cover.





11. NOTE: RH side shown, LH side similar.

Install the front crossmember and the 4 bolts (2 on each side).
^ Tighten to 70 Nm (52 ft. lbs.).

4.0L engine





12. Position the fuel line bracket in place and install the 6 engine-to-transmission retaining bolts.
^ Tighten to 48 Nm (35 ft. lbs.).





13. Install the 4 torque converter nuts.
^ Tighten to 35 Nm (26 ft. lbs.).





14. Install the starter motor.
^ Tighten to 25 Nm (18 ft. lbs.).





15. Install the lower transmission retaining bolts.
^ Tighten to 48 Nm (35 ft. lbs.).

All vehicles





16. Install a 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.
^ Tighten to 30 Nm (22 ft. lbs.).





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 (HO2S) 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.
^ Tighten to 5 Nm (44 ft. lbs.).





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 4 converter-to-manifold nuts.





29. Install the rear transmission mount bolts.
1 Position the rear transmission mount and exhaust hanger.
2 Install the rear mount bolts.
^ Tighten to 90 Nm (66 ft. lbs.).





30. NOTE: LH side shown, RH side similar.

Connect the 2 heated oxygen sensor electrical connectors.





31. Connect the 2 catalyst monitor sensor electrical connectors.





32. Position the crossmember in place and loosely install the 2 nuts to hold up the crossmember.





33. Install the RH side crossmember bolts.
^ Tighten to 70 Nm (52 ft. lbs.).





34. Install the LH side crossmember bolts.
^ Tighten to 70 Nm (52 ft. lbs.).





35. Remove the jackstand.





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

Install the 2 upper crossmember bolts (2 on each side).
^ Tighten to 70 Nm (52 ft. lbs.).





37. Tighten the rear transmission mount nuts.
^ Tighten to 90 Nm (66 ft. lbs.).





38. Install the RH heat shield and bolts.
^ Tighten to 20 Nm (15 ft. lbs.).





39. Install the LH heat shield bolts.
^ Tighten to 20 Nm (15 ft. lbs.).





40. Install the plastic shield on the right side of the crossmember near the fuel tank.
^ Tighten to 9 Nm (80 inch lbs.).





41. Tighten the 4 converter-to-manifold nuts.
^ Tighten to 40 Nm (30 ft. lbs.).





42. Using a new gasket, install the converter-to-muffler pipe and the heat shield. Install the bolts, springs and flag nuts.
^ Tighten to 40 Nm (30 ft. lbs.).





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 1st. 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.
^ Tighten to 30 Nm (22 ft. lbs.).





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 2 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 2 components.
^ Repeat this procedure several times.
^ If the space if not equal at any point in the attachment, remove and reinstall the driveshaft as described in this procedure.





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.
^ Tighten to 18 Nm (13 ft. lbs.).





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 TA-25 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 8 bolts.
1 Align the index marks.
2 Install the bolts.
^ Tighten to 112 Nm (83 ft. lbs.).





50. Install the shift cable and bracket.
^ Tighten to 40 Nm (30 ft. lbs.).
51. Use the following guidelines for installing the in-line transmission fluid 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 an in-line fluid filter, install a new in-line fluid filter kit.
^ 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 the in-line transmission fluid filter that is supplied.
^ Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit.

52. 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.
53. Position the fan shroud and install the bolts.
54. Carry out the fluid level check.
55. Verify that the shift cable is correctly adjusted.
56. Check the operation of the transmission and inspect for leaks.