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Automatic Transmission (6R80): Installation: Transmission

SPECIAL TOOLS

G06097256
 Retainer, Torque Converter
307-346 (T97T-7902-A)
G06139341
 Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® MERCON® LV Automatic Transmission Fluid
XT-10-QLVC (US); CXT-10-LV12 (Canada)		 MERCON® LV
Multi-Purpose Grease
Motorcraft® XL-5 (aerosol) and/or CRC® SL3151		 ESB-M1C93-B
Threadlock and Sealer
TA-25		 WSK-M2G351-A5

All vehicles 

NOTE: Prior to installing a new transmission or an overhauled transmission with a new main control, record the solenoid strategy identification tag. If a new main control was installed, install the replacement solenoid body tag over the original identification tag. For additional information, refer to SOLENOID BODY STRATEGY .
  1. NOTE: Prior to installation of the transmission, lubricate the torque converter pilot hub with multi-purpose grease or damage to the torque converter or engine crankshaft can occur.

    Lubricate the torque converter pilot hub with multi-purpose grease.

    Fig 1: Locating Grease Applying Area On Torque Converter Pilot Hub
    G06127674Courtesy of FORD MOTOR CO.
  2. If equipped, align the torque converter stud and flexplate hole near the paint marks at the 12 o'clock position.
    Fig 2: Locating Paint Marks On Flexplate Hole
    G07959423Courtesy of FORD MOTOR CO.
  3. Install the Torque Converter Retainer.
    Fig 3: Identifying Torque Converter Retainer
    G06127290Courtesy of FORD MOTOR CO.
  4. WARNING: Always secure transmission, transfer case, and axle assemblies to their service jack. Avoid obstructions while lowering and raising the jack. Improperly secured assemblies or contact with obstructions may cause the assembly to fall off the jack, which could result in serious personal injury.
    NOTE: The torque converter housing is piloted into position by dowels in the rear of the engine block. The torque converter must rest squarely against the flexplate. This indicates that the torque converter pilot is not binding in the engine crankshaft.
    NOTE: Make sure that the transmission jack makes contact on the outer ribs of the fluid pan.

    Position and secure the transmission on the high-lift transmission jack.

  5. NOTE: If transmission was disassembled, follow the add transmission fluid to the transmission steps. If transmission is being replaced, remove the transmission fluid fill plug and verify transmission is filled with transmission fluid.

    Add transmission fluid to the transmission.

    • Slightly tilt the transmission rearward.
    • Remove the transmission fluid fill plug transmission fluid level indicator assembly.
    • Add 11.35L (12 qt) of transmission fluid to the transmission through the transmission fluid fill hole.
    • Install the transmission fluid fill plug.
      • Tighten to 26 Nm (19 lb-ft).

    Vehicles equipped with a 5.0L (4V) engine 

  6. NOTE: Using the transmission jack, rotate the transmission approximately 25 degrees clockwise.

    Raise and position the transmission into the vehicle behind the engine.

  7. Position the transmission vehicle wiring harness and attach the wiring harness to the top of the transmission.
  8. Remove the Torque Converter Retainer.
    Fig 4: Identifying Torque Converter Retainer
    G06127290Courtesy of FORD MOTOR CO.
  9. Align the index mark on the torque converter with the index mark on the flexplate.
  10. NOTE: Make sure the torque converter is fully seated in the transmission before aligning the transmission to the engine.

    With the transmission in a horizontal position, move it toward the engine and position it on the dowel pins.

  11. Install the 5 transmission-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 5: Locating Transmission To Engine Mounting Bolts
      G07476075Courtesy of FORD MOTOR CO.
  12. Attach the wiring harness pin-type retainer to the transmission case.
    G07476074

    Vehicles equipped with a 3.7L engine 

  13. Raise and position the transmission into the vehicle behind the engine.
  14. Position the transmission vehicle wiring harness and attach the wiring harness to the top of the transmission.
  15. Remove the Torque Converter Retainer.
    Fig 6: Identifying Torque Converter Retainer
    G06127290Courtesy of FORD MOTOR CO.
  16. Align the index mark on the torque converter with the index mark on the flexplate.
  17. NOTE: Make sure the torque converter is fully seated in the transmission before aligning the transmission to the engine.

    With the transmission in a horizontal position, move it toward the engine and position it on the dowel pins.

  18. Install the 6 transmission-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G07476072

    All vehicles 

  19. Connect the transmission vehicle harness connector by pushing it in and twisting the outer shell to lock it in place.
    Fig 7: Locating Transmission Vehicle Harness Connector
    G06127319Courtesy of FORD MOTOR CO.
  20. Attach the selector lever cable to the transmission case.
    G07476070
  21. Install the crossmember and the transmission insulator and the 3 transmission insulator retaining bolts.
    • Tighten to 103 Nm (76 lb-ft).
      G07476068
  22. Install the 4 transmission crossmember retaining bolts.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 8: Locating Transmission Crossmember Bolts
      G07476069Courtesy of FORD MOTOR CO.

    Vehicles equipped with a 3.7L engine 

  23. Install 4 new flexplate-to-torque converter nuts.
    • Tighten to 40 Nm (30 lb-ft).
      G07476066
  24. Install the access cover and the 2 pin-type retainers.
    G07476065
  25. Raise the underbody shield and install the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
      G07474057
  26. NOTE: To make sure of correct starter installation, the upper bolt must be tightened first.

    Position the starter motor and install the 2 stud bolts finger-tight.

    • Tighten the upper stud bolt to 48 Nm (35 lb-ft).
    • Tighten the lower stud bolt to 48 Nm (35 lb-ft).
      G07476063
  27. Position the automatic transmission cooler tube bracket and install the nut.
    • Tighten to 12 Nm (106 lb-in).
      G07488341

    All vehicles 

  28. NOTE: Inspect the case to make sure that the old transmission fluid cooler tube O-rings are not stuck in the case.

    Install new transmission fluid cooler tube O-rings on the transmission fluid cooler tubes.

    Fig 9: Locating Transmission Fluid Cooler Tubes O-Rings
    G06127686Courtesy of FORD MOTOR CO.
  29. Position the transmission fluid cooler tubes and a new transmission fluid cooler tube bracket bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 10: Locating Transmission Fluid Cooler Tube Bracket Bolt
      G06127280Courtesy of FORD MOTOR CO.
  30. NOTE: RH shown, LH similar.

    Install the front crossmember brace and the 4 nuts (2 shown).

    • Tighten to 48 Nm (35 lb-ft).
      G07474214

    Vehicles equipped with a 5.0L (4V) engine 

  31. NOTE: Two of the bolts are shown, the third bolt is on top of starter.
    NOTE: To make sure of correct starter installation, the upper bolt must be tightened first.

    Position the starter motor and install the 3 bolts finger-tight.

    • Tighten the upper bolt to 25 Nm (18 lb-ft).
    • Tighten the lower 2 bolts to 25 Nm (18 lb-ft).
      G07476059
  32. Install 4 new flexplate-to-torque converter nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 11: Locating Flexplate To Torque Converter Nut
      G06127279Courtesy of FORD MOTOR CO.
  33. Install the rubber torque converter nut access plug.
    Fig 12: Locating Rubber Torque Converter Nut Access Plug
    G06127278Courtesy of FORD MOTOR CO.
  34. Position the lower splash shield and install the 9 bolts.
    Fig 13: Locating Lower Splash Shield Mounting Bolts
    G06395449Courtesy of FORD MOTOR CO.
  35. Install the flexplate inspection cover, the bolt and stud bolt.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 14: Locating Flexplate Inspection Cover Stud Bolt And Nut
      G07476055Courtesy of FORD MOTOR CO.
  36. Install the transmission fluid cooler bracket and nut to the flexplate inspection cover stud bolt.
    • Tighten to 12 Nm (106 lb-in).
      G07476054

    All vehicles 

  37. Install the selector lever cable bracket.
    1. Install the selector lever cable end onto the transmission manual control lever.
    2. Install the selector lever cable bracket and 2 bolts onto the transmission.
      • Tighten to 25 Nm (18 lb-ft).
        G07476053

    Vehicles equipped with a 5.0L (4V) engine 

  38. NOTE: If new driveshaft bolts or center bearing bolts are not available, coat the threads of the original bolts with threadlock and sealer and reuse the original washers and spacers.
    NOTE: The driveshaft flanges fit tightly on the transmission output flange pilot. To make sure that the driveshaft flange seats squarely on the transmission output flange, tighten the driveshaft flange bolts evenly in a cross pattern.
    NOTE: The center bearing spacers must be installed between the body and the center bearing bracket.

    Position the driveshaft and install the 2 center bearing spacers and bolts.

    • Install the new center bearing bolts finger-tight until after the front flange bolts are tightened to specifications.
      • Tighten to 48 Nm (35 lb-ft).
        Fig 15: Locating Center Bearing Bolts
        G06381996Courtesy of FORD MOTOR CO.
  39. Align the index-mark and install the 4 driveshaft flange bolts.
    • Tighten the new bolts evenly in a cross pattern.
      • Tighten to 103 Nm (76 lb-ft).
        Fig 16: Locating Driveshaft Flange To Transmission Bolts
        G06381987Courtesy of FORD MOTOR CO.
  40. Install the top 2 transmission-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G07476047
  41. Attach the wiring harness to the transmission stud.
    G07476046
  42. Install the engine appearance cover.
    Fig 17: Locating Engine Appearance Cover
    G07473994Courtesy of FORD MOTOR CO.
  43. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .

    Vehicles equipped with a 3.7L engine 

  44. NOTE: If new driveshaft flange bolts are not available, coat the threads of the original bolts with threadlock and sealer.
    NOTE: The driveshaft flanges fit tightly on the pinion flange pilots. To make sure that the driveshaft flanges seat squarely on the pinion flange pilots, tighten the driveshaft flange bolts evenly in a cross pattern.

    Align the index-mark and install the 4 driveshaft flange bolts.

    • Tighten the new bolts evenly in a cross pattern.
      • Tighten to 103 Nm (76 lb-ft).
        Fig 18: Locating Driveshaft Flange To Transmission Bolts
        G06381987Courtesy of FORD MOTOR CO.
  45. Install the top 2 and side 2 transmission-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G07476041
  46. Attach the wiring harness to the 2 transmission studs.
    G07476040
  47. If equipped, install the engine appearance cover.
  48. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .

    All vehicles 

  49. If equipped, install the strut tower cross brace and the 4 nuts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 19: Locating Strut Tower Cross Brace Nuts
      G07473993Courtesy of FORD MOTOR CO.
  50. Verify the selector lever cable is correctly adjusted. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS .
  51. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.
  52. If a new transmission or a new main control was installed, the solenoid body strategy must be updated. For additional information, refer to SOLENOID BODY STRATEGY .
  53. If the transmission was overhauled, the adaptive drive cycle must be updated. For additional information, refer to SHIFT POINT ROAD TEST .
  54. While driving the vehicle, use the scan tool to verify that the Transmission Fluid Temperature (TFT) has reached a temperature of 88°C (190°F). This will circulate the transmission fluid through the torque converter and the transmission fluid cooling system, eliminating any trapped air in the transmission fluid cooling system.
    • With the engine idling (600-750 rpm) in PARK, verify that the TFT is between 80°C-85°C (176°F-185°F).
  55. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case.
    Fig 20: Locating Transmission Fluid Fill Plug
    G06127144Courtesy of FORD MOTOR CO.
  56. Separate the transmission fluid level indicator from the transmission fluid fill plug.
    Fig 21: Locating Transmission Fluid Level Indicator And Fill Plug
    G06127148Courtesy of FORD MOTOR CO.
  57. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established.
    Fig 22: Locating Transmission Fluid Fill Plug
    G06127154Courtesy of FORD MOTOR CO.
  58. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional Transmission Fluid or Removing Transmission Fluid. For additional information, refer to TRANSMISSION FLUID DRAIN AND REFILL .

    Install the transmission fluid fill plug.

    • Tighten to 35 Nm (26 lb-ft).
      Fig 23: Locating Transmission Fluid Fill Plug
      G06127144Courtesy of FORD MOTOR CO.
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