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Home >> Mercury Truck >> 2007 >> Mountaineer AWD V6-4.0L VIN K >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Removal and Replacement >> Installation

Installation

Transmission - Four Wheel Drive (4WD)

Special Tool(s):





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

Install the special tool if not done during assembly.





3. Raise and position the transmission and transfer case to the back of the engine.
4. Remove the special tool.





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





6. Install 4 new torque converter nuts.
^ Tighten to 44 Nm (32 ft. lbs.)





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





8. Install the ground cable and nut.
^ Tighten to 13 Nm (10 ft. lbs.)





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





10. Install a jackstand under the transfer case.





11. Remove the transmission jack from under the transmission.

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

CAUTION: Hold the transmission case fittings with a backup wrench.

Install the transmission fluid cooler tubes.
^ Tighten to 40 Nm (30 ft. lbs.)





13. Position the wire harness and install the retainers.





14. Connect the digital transmission range (TR) sensor electrical connector.





15. Move the rubber boot back over the connector.





16. Connect the LH heated oxygen sensor (HO2S) to the transmission and install the wire harness retainer.





17. 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 inch lbs.)





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





19. Connect the RH HO2S to the transmission.





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





21. Connect the turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor and intermediate shaft speed sensor electrical connectors.





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

Install the selector lever cable and bracket.
^ Tighten to 40 Nm (30 ft. lbs.)





23. NOTE: If the shield is loose on the cable, install a new shield.

Install the cable shield.





24. NOTE: LH side shown, RH similar.

If removed, install the transmission insulator.
^ Tighten to 90 Nm (66 ft. lbs.)





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

NOTE: This step may require an assistant.

Position the catalytic 3-way converter assembly and loosely install the 4 converter-to-manifold nuts.





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

Connect the 2 HO2S electrical connectors.





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

Connect the 2 catalyst monitor sensor electrical connectors.





28. Position the crossmember in place and loosely install the 2 nuts to support the crossmember.





29. Install the 4 RH side crossmember bolts and the nut.
^ Tighten to 70 Nm (52 ft. lbs.)





30. Install the 4 LH side crossmember bolts and the nut.
^ Tighten to 70 Nm (52 ft. lbs.)





31. Remove the jackstand.





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





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





34. If equipped, install the RH exhaust heat shield.
^ Tighten to 20 Nm (15 ft. lbs.)





35. NOTE: RH shown, LH similar.

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





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





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





38. Install the driveshafts.
39. Use these 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.
40. If equipped, position the skid plate and install the 4 bolts.
^ Tighten to 24 Nm (18 ft. lbs.)





41. 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. For additional information, refer to Battery.
42. Position the fan shroud and install the bolts.
^ Tighten to 7 Nm (62 inch lbs.)
43. Position the coolant expansion tank and install the bolts.
^ Tighten to 7 Nm (62 inch lbs.)
44. Carry out the fluid level check.
45. Verify that the selector lever cable is correctly adjusted.
46. Check the operation of the transmission and inspect for leaks.
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