LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2002 >> Explorer 4.0 K, 4WD, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul Automatic Transmission >> Assembly >> Transmission

Overhaul Automatic Transmission: Assembly: Transmission

Fig 1: Special Tool(s) (1 Of 4)
G01672390Courtesy of FORD MOTOR CO.
Fig 2: Special Tool(s) (2 Of 4)
G01672391Courtesy of FORD MOTOR CO.
Fig 3: Special Tool(s) (3 Of 4)
G01672392Courtesy of FORD MOTOR CO.
Fig 4: Special Tool(s) (4 Of 4)
G01672393Courtesy of FORD MOTOR CO.
Fig 5: Materials
G01672394Courtesy of FORD MOTOR CO.

All vehicles

  1. Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.
  2. Inspect the transmission case for the following:
    • stripped bolt hole threads
    • gasket and mating surfaces for burrs or nicks
    • obstructions to vent and fluid passages
    • cracks or warpage
    Fig 6: Inspecting Transmission Case
    G01672395Courtesy of FORD MOTOR CO.

    4x2 vehicles 

  3. Inspect the extension housing for cracks, burrs or warpage.
    Fig 7: Inspecting Extension Housing
    G01672396Courtesy of FORD MOTOR CO.

    4x4 vehicles 

  4. Inspect the extension housing for cracks, burrs or warpage.
    Fig 8: Inspecting Extension Housing
    G01672397Courtesy of FORD MOTOR CO.

    All vehicles 

  5. Inspect case bearing for damage. Install a new component as necessary. Follow Steps 5-8 if replacing the case bearing. If not replacing the case bearing, proceed to Step 9.
    6. Fig 9: Inspecting Case Bearing
    G01672398Courtesy of FORD MOTOR CO.
  6. Using the special tool, remove the case bearing.
    • Use an oil stone to remove any nicks or burrs in the bearing case bore.
    7. Fig 10: Removing Case Bearing
    G01672399Courtesy of FORD MOTOR CO.
  7. Assemble the special tools.
    8. Fig 11: Assembling Installation Tools
    G01672400Courtesy of FORD MOTOR CO.
    CAUTION: Make sure bearing seal ring is facing the drive handle.
  8. Install the bearing on the special tools.
    9. Fig 12: Installing Case Bearing On Installation Tool
    G01672401Courtesy of FORD MOTOR CO.
  9. Using the special tool, tap case bearing into case bearing bore.
    10. Fig 13: Installing Case Bearing
    G01672402Courtesy of FORD MOTOR CO.
    WARNING: Make sure the lock pin on bench-mounted holding fixture is secure. Failure to follow these instructions may result in personal injury.
  10. Using the special tool, install the transmission into the bench with the converter housing facing up.
    11. Fig 14: Mounting Transmission Case To Bench
    G01672403Courtesy of FORD MOTOR CO.
  11. Using the special tool, install the manual control lever shaft seal and lubricate it with petroleum jelly.
    12. Fig 15: Installing Manual Control Lever Shaft Seal
    G01672404Courtesy of FORD MOTOR CO.
  12. Install the intermediate servo piston and spring.
    • Lubricate the servo bore with clean automatic transmission fluid.
    13. Fig 16: Installing Intermediate Servo Piston & Spring
    G01672405Courtesy of FORD MOTOR CO.
  13. Using the special tool, install the retaining ring.
    14. Fig 17: Installing Intermediate Servo Retaining Ring
    G01672406Courtesy of FORD MOTOR CO.
  14. Install the overdrive band servo piston and spring.
    • Lubricate the servo bore with clean automatic transmission fluid.
    15. Fig 18: Installing Overdrive Band Servo Piston & Spring
    G01672407Courtesy of FORD MOTOR CO.
  15. Using the special tools, install the retaining ring.
    16. Fig 19: Installing Overdrive Band Servo Retaining Ring
    G01672408Courtesy of FORD MOTOR CO.
  16. Install the parking lever rod.
    17. Fig 20: Installing Parking Lever Rod
    G01672409Courtesy of FORD MOTOR CO.
  17. Install the manual control lever.
    18. Fig 21: Installing Manual Control Lever
    G01672410Courtesy of FORD MOTOR CO.
  18. Assemble the manual valve inner lever and parking lever actuating rod as shown.
    19. Fig 22: Assembling Manual Valve Inner Lever To Parking Lever Actuating Rod
    G01672411Courtesy of FORD MOTOR CO.
    CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.
  19. Install the manual control lever shaft.
    20. Fig 23: Installing Manual Control Lever Shaft
    G01672412Courtesy of FORD MOTOR CO.
  20. Install the manual valve inner lever onto the manual shaft and loosely install the nut.
    21. Fig 24: Installing Manual Valve Inner Lever Onto Manual Shaft
    G01672413Courtesy of FORD MOTOR CO.
    CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.
    NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case.
  21. Install the manual control lever shaft spring pin.
    • Tap the manual control lever shaft spring pin into the transmission case.
    22. Fig 25: Installing Manual Control Lever Shaft Spring Pin
    G01672414Courtesy of FORD MOTOR CO.
    CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.
  22. Tighten the nut.
    23. Fig 26: Tightening Manual Control Lever Shaft Nut
    G01672415Courtesy of FORD MOTOR CO.
    CAUTION: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated.
  23. Install the output shaft thrust washer (No. 11).
    • Coat the output shaft thrust washer with petroleum jelly.
    24. Fig 27: Installing Output Shaft Thrust Washer
    G01672416Courtesy of FORD MOTOR CO.
  24. Install the park gear on the output shaft.
    25. Fig 28: Installing Park Gear
    G01672417Courtesy of FORD MOTOR CO.
  25. Install the output shaft and park gear.
    26. Fig 29: Installing Output Shaft
    G01672418Courtesy of FORD MOTOR CO.
    CAUTION: Make sure band is resting on the two anchor pins in the case.
  26. Install the low/reverse band over the low/reverse brake drum.
    27. Fig 30: Installing Low/Reverse Band
    G01672419Courtesy of FORD MOTOR CO.
  27. Install the low/reverse brake drum.
    • Rotate the low/reverse brake drum clockwise to install.
    28. Fig 31: Installing Low/Reverse Brake Drum
    G01672420Courtesy of FORD MOTOR CO.
    NOTE: The reverse band actuating lever must fit into the notches in the band.
  28. Install the reverse band actuating lever into the reverse band.
    29. Fig 32: Installing Reverse Band Actuating Lever
    G01672421Courtesy of FORD MOTOR CO.
  29. Install the reverse band actuating lever shaft into the case and into the reverse band actuating lever.
    30. Fig 33: Installing Reverse Band Actuating Lever Shaft
    G01672422Courtesy of FORD MOTOR CO.
  30. Install the No.10 needle bearing into the case.
    31. Fig 34: Installing Needle Bearing Into Case
    G01672423Courtesy of FORD MOTOR CO.
    CAUTION: Do not damage the seal against the case during assembly.
  31. Install the output shaft ring gear, hub, and seal.
    32. Fig 35: Installing Output Shaft Ring Gear, Hub & Seal
    G01672424Courtesy of FORD MOTOR CO.
    CAUTION: Always install a new output shaft retaining ring.
  32. Install a new output shaft retaining ring.
    33. Fig 36: Installing Output Shaft Retaining Ring
    G01672425Courtesy of FORD MOTOR CO.
    NOTE: Install the output shaft sleeve with the cone facing up. This sleeve will snap into place when correctly installed.
  33. Install the output shaft sleeve.
    34. Fig 37: Installing Output Shaft Sleeve
    G01672426Courtesy of FORD MOTOR CO.
  34. Install low/reverse planetary carrier needle bearing (No. 9) onto the output shaft ring gear and hub assembly.
    35. Fig 38: Installing Low/Reverse Planetary Carrier Needle Bearing
    G01672427Courtesy of FORD MOTOR CO.
    CAUTION: Make sure the needle bearings stay in place.
  35. Install the low/reverse planetary assembly.
    36. Fig 39: Installing Low/Reverse Planetary Assembly
    G01672428Courtesy of FORD MOTOR CO.
    CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.
  36. Install the retaining ring.
    37. Fig 40: Installing Retaining Ring
    G01672429Courtesy of FORD MOTOR CO.
  37. Install the No. 8 thrust bearing.
    38. Fig 41: Installing Thrust Bearing
    G01672430Courtesy of FORD MOTOR CO.
  38. Install the spacer on the input shell, using petroleum jelly to hold it in place.
    39. Fig 42: Installing Spacer On Input Shell
    G01672431Courtesy of FORD MOTOR CO.
  39. Install the input shell and sun gear assembly.
    40. Fig 43: Installing Input Shell & Sun Gear Assembly
    G01672432Courtesy of FORD MOTOR CO.
    NOTE: The No. 13 bearing must be properly seated in the forward planet assembly so the sun gear can be installed correctly.
  40. Install the forward planetary assembly.
    41. Fig 44: Installing Forward Planetary Assembly
    G01672433Courtesy of FORD MOTOR CO.
  41. Install the No. 7 forward planet thrust bearing into the forward ring gear and hub assembly. Use petroleum jelly to hold the bearing in place.
    42. Fig 45: Installing Forward Planet Thrust Bearing
    G01672434Courtesy of FORD MOTOR CO.
  42. Install the No. 6B forward clutch thrust washer onto the forward ring gear hub.
    43. Fig 46: Installing Forward Clutch Thrust Washer
    G01672435Courtesy of FORD MOTOR CO.
  43. Install the forward ring gear and hub as an assembly.
    44. Fig 47: Installing Forward Ring Gear & Hub Assembly
    G01672436Courtesy of FORD MOTOR CO.
  44. Install the No. 6A forward ring gear hub thrust bearing into the forward ring gear and hub.
    45. Fig 48: Installing Forward Ring Gear Hub Thrust bearing
    G01672437Courtesy of FORD MOTOR CO.
  45. Install the forward clutch cylinder.
    46. Fig 49: Installing Forward Clutch Cylinder
    G01672438Courtesy of FORD MOTOR CO.
  46. Install the No. 5 thrust bearing.
    47. Fig 50: Installing Thrust Bearing
    G01672439Courtesy of FORD MOTOR CO.
  47. Install the direct clutch drum.
    48. Fig 51: Installing Direct Clutch Drum
    G01672440Courtesy of FORD MOTOR CO.
  48. Using the special tool, measure from the top of the gauge bar to center support ledge in case at four places 90 degrees apart.
    • Add the four measurements, divide by four, and record as dimension A.
    49. Fig 52: Measuring Center Support Height
    G01672441Courtesy of FORD MOTOR CO.
    CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.
  49. Install the special tool.
    1. Install the special tool and the bolts using the two pump screw locations at approximately 6 and 12 o'clock positions.
    2. Tighten the center screw.
    50. Fig 53: Installing Special Tool
    G01672442Courtesy of FORD MOTOR CO.
    NOTE: Align the disc holes on special tool with the slot in gauge bar for correct measurement.
  50. Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension B. Repeat measurement 180 degrees opposite side of the special tool and record as dimension C.
    51. Fig 54: Measuring Drum Bearing Surface Depth
    G01672443Courtesy of FORD MOTOR CO.
  51. Add dimension B to C, divide by two and record as dimension D.
  52. Subtract A from D, and record as dimension E.
  53. Select bearing from the following chart, using dimension E.
    54. Fig 55: Bearing Thickness Table
    G01672444Courtesy of FORD MOTOR CO.
    NOTE: Make sure that the intermediate band apply strut is aligned with the band notch.
    NOTE: If the intermediate band is reused, it must be installed in the same position as when removed.
    NOTE: The intermediate band is new, and dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
  54. Install the intermediate band.
    55. Fig 56: Installing Intermediate Band
    G01672445Courtesy of FORD MOTOR CO.
  55. Install the intermediate band anchor strut.
    56. Fig 57: Installing Intermediate Band Anchor Strut
    G01672446Courtesy of FORD MOTOR CO.
    CAUTION: If the strut is installed incorrectly, transmission damage will occur.
  56. Check to make sure that the intermediate band anchor strut is installed in the correct orientation to the case and adjustment screw.
    57. Fig 58: Checking Intermediate Band Anchor Strut For Correct Orientation
    G01672447Courtesy of FORD MOTOR CO.
  57. Loosely install the screw.
    58. Fig 59: Installing Intermediate Band Anchor Screw
    G01672448Courtesy of FORD MOTOR CO.
  58. Install the intermediate band apply strut.
    59. Fig 60: Installing Intermediate Band Apply Strut
    G01672449Courtesy of FORD MOTOR CO.
    CAUTION: If the strut is installed incorrectly, transmission damage will occur.
  59. Check to make sure that the intermediate band apply strut is installed in the correct orientation to the case and piston rod.
    60. Fig 61: Checking Intermediate Band Apply Strut For Correct Orientation
    G01672450Courtesy of FORD MOTOR CO.
  60. Install the selected No. 4 thrust washer on the direct clutch drum.
    • Coat the thrust washer with petroleum jelly.
    61. Fig 62: Installing Thrust Washer On Direct Clutch Drum
    G01672451Courtesy of FORD MOTOR CO.
    NOTE: Align the center support screw hole with correct case hole.
  61. Install the center support.
    62. Fig 63: Installing Center Support
    G01672452Courtesy of FORD MOTOR CO.
  62. Install the center support locknut and cage.
    63. Fig 64: Installing Center Support Lock Nut & Cage
    G01672453Courtesy of FORD MOTOR CO.
  63. Loosely install the screw.
    64. Fig 65: Installing Center Support Screw
    G01672454Courtesy of FORD MOTOR CO.
    CAUTION: Install the center support retaining ring with the tapered side facing up.
    CAUTION: Make sure the notch opening is not obstructed by the center support retaining ring.
  64. Install the center support retaining ring.
    1. Make sure the center support retaining ring is installed with the tapered side facing up.
    2. Make sure the opening of the center support retaining ring is positioned correctly.
    65. Fig 66: Installing Center Support Retaining Ring
    G01672455Courtesy of FORD MOTOR CO.
  65. Install the center shaft thrust bearing (No. 3).
    66. Fig 67: Installing Center Shaft Thrust Bearing
    G01672456Courtesy of FORD MOTOR CO.
  66. Install the overdrive ring gear, overdrive one-way clutch and center shaft assembly.
    67. Fig 68: Installing Overdrive Ring Gear
    G01672457Courtesy of FORD MOTOR CO.
    CAUTION: Do not bend the trigger wheel. Make sure that the No. 2 thrust bearing is in this assembly.
  67. Install the planetary gear overdrive carrier.
    68. Fig 69: Installing Planetary Gear Overdrive Carrier
    G01672458Courtesy of FORD MOTOR CO.
  68. Install the overdrive brake drum and coast clutch drum assembly.
    69. Fig 70: Installing Overdrive Brake Drum & Coast Clutch Drum Assembly
    G01672459Courtesy of FORD MOTOR CO.
    NOTE: If the overdrive band is reused, it must be installed in the same position as when removed.
    NOTE: Make sure that the overdrive band apply strut is aligned with the band notch.
    NOTE: The overdrive band is new, and dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
  69. Install the overdrive band.
    70. Fig 71: Installing Overdrive Band
    G01672460Courtesy of FORD MOTOR CO.
  70. Install the overdrive anchor strut.
    71. Fig 72: Installing Overdrive Anchor Strut
    G01672461Courtesy of FORD MOTOR CO.
    CAUTION: If the strut is installed incorrectly, transmission damage will occur.
  71. Check to make sure that the overdrive band anchor strut is installed in the correct orientation to the case and adjustment screw.
    72. Fig 73: Checking Overdrive Band Anchor Strut For Correct Orientation
    G01672462Courtesy of FORD MOTOR CO.
  72. Loosely install the screw.
    73. Fig 74: Installing Overdrive Band Anchor Screw
    G01672463Courtesy of FORD MOTOR CO.
  73. Install the overdrive apply strut.
    74. Fig 75: Installing Overdrive Apply Strut
    G01672464Courtesy of FORD MOTOR CO.
    CAUTION: If the strut is installed incorrectly, transmission damage will occur.
  74. Check to make sure that the overdrive band apply strut is installed in the correct orientation to the case and piston rod.
    75. Fig 76: Checking Overdrive Band Apply Strut For Correct Orientation
    G01672465Courtesy of FORD MOTOR CO.
    CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.
  75. Install the special tool.
    1. Install the special tool and the bolts using the two pump screw locations at approximately 6 and 12 o'clock positions.
      2. Fig 77: Installing Special Tool
      G01672466Courtesy of FORD MOTOR CO.
    2. Tighten the center screw.
    76. NOTE: Align the disc holes on special tool with the slot in gauge bar for correct measurement.
  76. Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension A. Repeat measurement 180 degrees opposite side of the special tool and record as dimension B.
    77. Fig 78: Measuring Drum Bearing Surface Depth
    G01672467Courtesy of FORD MOTOR CO.
  77. Add dimension A to B, divide by two and record as dimension C.
  78. Subtract the thickness of the gauge bar 17.78 mm (0.71 in) from dimension C, and record as dimension D.
  79. Select the No. 1 thrust bearing from the following chart using dimension D.
    80. Fig 79: Thrust Bearing Thickness Table
    G01672468Courtesy of FORD MOTOR CO.
  80. Install the selected No. 1 fluid pump input thrust washer.
    • Coat the fluid pump input thrust washer with petroleum jelly.
    81. Fig 80: Installing Fluid Pump Input Thrust Washer
    G01672469Courtesy of FORD MOTOR CO.
  81. Install the special tools into the transmission case.
    82. Fig 81: Installing Fluid Pump Guide Pins
    G01672470Courtesy of FORD MOTOR CO.
  82. Install the pump gasket.
    83. Fig 82: Installing Fluid Pump Gasket
    G01672471Courtesy of FORD MOTOR CO.
    CAUTION: Make sure that the fluid pump inlet thrust washer (No. 1), selective thrust washer, fluid pump gasket, and the fluid pump-to-case O-ring seal remain in the correct position throughout this step.
  83. Install the fluid pump.
    84. Fig 83: Installing Fluid Pump
    G01672472Courtesy of FORD MOTOR CO.
    CAUTION: The special tools must be used to correctly align the pump with the adapter plate to reduce gear noise, bushing failure, and leakage.
  84. Using the special tool, align the fluid pump to the adapter plate.
    85. Fig 84: Aligning Fluid Pump To Adapter Plate
    G01672473Courtesy of FORD MOTOR CO.
  85. Install screws. Tighten the screws in a star pattern.
    86. Fig 85: Installing Fluid Pump Screws
    G01672474Courtesy of FORD MOTOR CO.
  86. Remove the special tools and install the two remaining screws.
    87. Fig 86: Installing 2 Remaining Screws
    G01672475Courtesy of FORD MOTOR CO.
    CAUTION: Do not allow overdrive band adjustment screw to back out. Band strut could fall out of position.
    CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.
  87. Install a new locknut on the band adjustment screw.
    88. Fig 87: Installing Band Adjustment Locknut
    G01672476Courtesy of FORD MOTOR CO.
    CAUTION: The overdrive servo must be installed prior to band adjustment.
  88. Using the special tool, tighten the overdrive band adjustment screw. Then back off the screw exactly (2) turns and hold that position.
    89. Fig 88: Adjusting Overdrive Band
    G01672477Courtesy of FORD MOTOR CO.
  89. Tighten the overdrive band locknut.
    1. Hold the overdrive band adjustment screw stationary.
    2. Tighten the overdrive band locknut.
    90. Fig 89: Tightening Overdrive Band Locknut
    G01672478Courtesy of FORD MOTOR CO.
    CAUTION: Do not allow the intermediate band adjusting screw to back out. Band strut could fall out of position.
    CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.
  90. Install new nut on the band adjustment screw.
    91. Fig 90: Installing Intermediate Band Locknut
    G01672479Courtesy of FORD MOTOR CO.
    CAUTION: The intermediate servo must be installed prior to band adjustment.
  91. Tighten the intermediate band adjustment screw. Then back off the screw exactly (2) turns and hold that position.
    92. Fig 91: Adjusting Intermediate Band
    G01672480Courtesy of FORD MOTOR CO.
  92. Tighten the intermediate band locknut.
    1. Hold the intermediate band adjustment screw stationary.
    2. Tighten the intermediate band locknut.
    93. Fig 92: Tightening Intermediate Band Locknut
    G01672481Courtesy of FORD MOTOR CO.
  93. Tighten the center support screw.
    94. Fig 93: Tightening Center Support Screw
    G01672482Courtesy of FORD MOTOR CO.
  94. Install the special tools into the transmission case.
    95. Fig 94: Installing Valve Body Aligning Tools
    G01672483Courtesy of FORD MOTOR CO.
  95. Install the main control valve body and loosely install the screws.
    96. Fig 95: Installing Main Control Valve Body
    G01672484Courtesy of FORD MOTOR CO.
  96. Remove the special tools, and loosely install the screw.
    97. Fig 96: Installing Remaining Screws
    G01672485Courtesy of FORD MOTOR CO.
  97. Tighten the screws in the sequence shown.
    98. Fig 97: Main Control Valve Body Tightening Sequence
    G01672486Courtesy of FORD MOTOR CO.
  98. With the manual lever in the NEUTRAL position, install the manual valve detent spring.
    99. Fig 98: Installing Manual Valve Detent Spring
    G01672487Courtesy of FORD MOTOR CO.
  99. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid.
    100. Fig 99: Installing Solenoid Body O-Ring Seals
    G01672488Courtesy of FORD MOTOR CO.
    CAUTION: Inspect the transmission case bore to make sure it is free of debris and not damaged. If damaged, transmission leak may occur.
  100. Install the solenoid body. Tighten bolts in sequence shown.
    101. Fig 100: Installing Solenoid Body
    G01672489Courtesy of FORD MOTOR CO.
  101. Install the reverse servo. Tighten the bolts in the sequence shown in two stages.
    • Stage 1: Tighten bolts to 5 Nm (44 lb-in).
    • Stage 1: Tighten bolts to 11 Nm (8 lb-ft).
    102. Fig 101: Installing Reverse Servo
    G01672490Courtesy of FORD MOTOR CO.
    CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged.
    NOTE: Make sure that the fluid filter seals are correctly seated on the filter.
  102. Lubricate the seals and install the transmission fluid filter.
    103. Fig 102: Installing Transmission Fluid Filter
    G01672491Courtesy of FORD MOTOR CO.
    NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.
  103. Install the transmission fluid pan and gasket and loosely install the screws.
    104. Fig 103: Installing Transmission Fluid Pan
    G01672492Courtesy of FORD MOTOR CO.
  104. Tighten the 16 screws in a crisscross sequence.
    105. Fig 104: Tightening Transmission Fluid Pan
    G01672493Courtesy of FORD MOTOR CO.
    NOTE: The 4x2 is shown, the 4x4 is similar.
  105. Install the parking pawl assembly and gasket.
    1. Install the parking pawl shaft.
    2. Install the parking pawl return spring.
    3. Install the parking pawl.
    4. Install a new gasket.
      5. Fig 105: Installing Parking Pawl Assembly & Gasket
      G01672494Courtesy of FORD MOTOR CO.

    4x2 vehicles 

  106. Install the extension housing.
    Fig 106: Installing Extension Housing
    G01672495Courtesy of FORD MOTOR CO.
  107. Using the special tool, install the extension housing seal.
    Fig 107: Installing Extension Housing Seal
    G01672496Courtesy of FORD MOTOR CO.

    4x4 vehicles 

  108. Install the extension housing.
    109. Fig 108: Installing Extension Housing
    G01672497Courtesy of FORD MOTOR CO.
  109. Using the special tool, install the extension housing seal.
    Fig 109: Installing Extension Housing Seal
    G01672498Courtesy of FORD MOTOR CO.

    All vehicles 

    110. CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor.
  110. Install the digital transmission range (TR) sensor and loosely install the screws.
    111. Fig 110: Installing Digital TR Sensor
    G01672499Courtesy of FORD MOTOR CO.
    CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.
    NOTE: The manual lever must be in the NEUTRAL position.
  111. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.
    112. Fig 111: Aligning Digital TR Sensor
    G01672500Courtesy of FORD MOTOR CO.
  112. Install the outer manual lever.
    113. Fig 112: Installing Outer Manual Lever
    G01672501Courtesy of FORD MOTOR CO.
    CAUTION: The splines of the input shaft are not the same length on both ends. The shaft end with the shorter splines goes into the fluid pump.
  113. Install the input shaft.
    114. Fig 113: Installing Input Shaft
    G01672502Courtesy of FORD MOTOR CO.
  114. Using the special tool, make sure that the fluid pump gear seal ring is fully seated.
    115. Fig 114: Ensuring Fluid Pump Gear Seal Ring Is Fully Seated
    G01672503Courtesy of FORD MOTOR CO.
  115. Remove the special tool.
    116. Fig 115: Removing Fluid Pump Gear Seal Ring Installer Tool
    G01672504Courtesy of FORD MOTOR CO.
    CAUTION: Do not damage the fluid pump gear O-ring seal when installing torque converter.
    CAUTION: Make sure the converter hub is fully engaged in the pump support and gear and rotates freely. Do not damage the hub seal.
    CAUTION: If the torque converter slides out, the hub seal may be damaged.
  116. Lubricate the converter hub with clean automatic transmission fluid.
    117. Fig 116: Lubricating Converter Hub
    G01672505Courtesy of FORD MOTOR CO.
    WARNING: The torque converter can fall out if the transmission is tipped. Failure to follow these instructions may cause personal injury.
  117. Using the special tools, install the torque converter by pushing and rotating.
    118. Fig 117: Installing Torque Converter
    G01672506Courtesy of FORD MOTOR CO.
  118. Lubricate the torque converter pilot hub with multi-purpose grease.
    119. Fig 118: Lubricating Torque Converter Pilot Hub
    G01672507Courtesy of FORD MOTOR CO.
    CAUTION: The special tool must be used to correctly align the adapter plate to the converter or transmission damage could occur.
    In order to correctly install the special service tool, it must be installed using one round and one oblong hole. Using two oblong holes will cause damage to the transmission.
    NOTE: Align the identifying mark made on the nut, stud, and adapter plate during disassembly for correct installation.
  119. If the vehicle is equipped, use the special tool to install the torque converter flex plate adapter assembly and eight nuts.
    120. Fig 119: Installing Torque Converter Flex Plate Adapter
    G01672508Courtesy of FORD MOTOR CO.
  120. Install two torque converter flex plate adapter nuts.
    121. Fig 120: Installing 2 Remaining Torque Converter Flex Plate Adapter Nuts
    G01672509Courtesy of FORD MOTOR CO.
  121. Using one of the speed sensor holes, fill the transmission with 8.5L (9 quarts) of automatic transmission fluid.
    122. Fig 121: Filling Transmission
    G01672510Courtesy of FORD MOTOR CO.
    NOTE: Inspect O-ring seal for damage. Install new if damaged. Lubricate the O-ring seals with petroleum jelly to prevent damage to the O-ring seals.
  122. Install the sensors.
    123. Fig 122: Installing Sensors
    G01672511Courtesy of FORD MOTOR CO.
  123. Before installing transmission, make sure that the transmission cooling system (tube and cooler) have been thoroughly flushed. If contamination cannot be removed or correct flow cannot be obtained, install a new cooler and/or tubes. See REMOVAL & INSTALLATION .
scientia non olet · About LEMON Manuals