5R55S - Automatic Transaxle/Transmission

Transmission - Four Wheel Drive (4WD)





1. WARNING: Secure the assembly to the jack. Avoid any obstructions while lowering and raising the jack. Contact with obstructions may cause the assembly to fall off the jack, which may result in serious 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 lb-ft).





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 lb-ft).





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





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





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





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





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 transmission fluid cooler tubes, otherwise damage to the transmission fluid cooler tubes and the transmission may result.

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

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





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 digital TR sensor electrical 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 transmission control solenoid body assembly if the screw is tightened above the specification.

NOTE: Always install new O-ring seals on the transmission solenoid body harness connector.

NOTE: Clean the area around transmission solenoid body harness connector to prevent contamination of the transmission solenoid body harness 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 solenoid body harness connector and connect the transmission solenoid body harness connector.
^ Tighten to 5 Nm (44 lb-inch).





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 selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.

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





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

Install the selector lever cable shield.





24. NOTE: LH side shown, RH similar.

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





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 lb-ft).





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





31. Remove the jackstand.





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





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





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





35. NOTE: RH shown, LH similar.

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





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 lb-ft).





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





38. Install the driveshafts.
39. 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 transmission fluid filter, install a new in-line transmission fluid filter.
^ If the transmission was overhauled and the vehicle was not equipped with an in-line transmission fluid filter, install a new in-line transmission fluid filter kit.
^ If the transmission is being installed for a non-internal repair, do not install an in-line transmission filter or filter kit.
^ If installing a new or a Ford-authorized remanufactured transmission, install a new in-line transmission fluid filter.
^ 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 lb-ft).





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.
42. Position the fan shroud and install the bolts.
^ Tighten to 7 Nm (62 lb-inch).
43. Position the coolant expansion tank and install the bolts.
^ Tighten to 7 Nm (62 lb-inch).
44. Carry out the fluid level check. Transmission Fluid Level Check
45. Verify that the selector lever cable is correctly adjusted.
46. Check the operation of the transmission and inspect for leaks.