Removal And Installation: Transmission: Installation

All vehicles 

1. 1.
   
   If removed, inspect the transmission mounted transmission fluid cooler tube backing rings and seals for damage and install new backing rings or seals if necessary.

   1. 1.
      
      Install the backing ring (7J324)

   1. 2.
      
      Lubricate and install the seal (7D285)

      Material

      : Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (MERCON® LV) (WSS-M2C938-A)

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1. 2.
   
   Install the transmission mounted transmission fluid cooler tubes, the new bolts and the nuts.

   1. 1.
      
      Torque

      : 97 lb.in (11 Nm)

   1. 2.
      
      Torque

      : 80 lb.in (9 Nm)

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1. 3.
   
   Install the transmission support insulator bracket and the bolts.

   Torque

   : 46 lb.ft (63 Nm)

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1. 4.
   
   Install the special tool.

   Use Special Service Tool: 307-566 Retainer, Torque Converter.

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1. 5.
   
   Lubricate the torque converter pilot hub with Multi-Purpose Grease.

   Material

   : Motorcraft® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)

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1. 6.
   
   
   NOTE: If the transmission is not positioned on the dowel pins, damage to the transmission may occur.

   If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.

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1. 7.
   
   
   NOTE: Secure the transmission to the transmission jack with a safety strap.

   Support the transmission with a transmission jack.

   Use the General Equipment: Transmission Jack

1. 8.
   
   Position the transmission behind the engine and remove the special tool.

   Use Special Service Tool: 307-566 Retainer, Torque Converter.

   Use the General Equipment: Transmission Jack

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1. 9.
   
   Align the index-mark made during removal.

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1. 10.
   
   Install the LH and the RH transmission-to-engine bolts.

   Torque

   : 35 lb.ft (48 Nm)

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1. 11.
   
   Install the lower transmission-to-engine bolts.

   Torque

   : 35 lb.ft (48 Nm)

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1. 12.
   
   
   NOTE: Only rotate the engine in a clockwise direction or engine damage will occur.
   NOTE: The torque converter nuts are accessed from the top of the vehicle.

   Using a magnetic socket install the new torque converter nuts.

   Use the General Equipment: Magnetic Socket

   Torque

   : 30 lb.ft (40 Nm)

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1. 13.
   
   Install the upper transmission-to-engine bolts.

   Torque

   : 35 lb.ft (48 Nm)

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1. 14.
   
   
   NOTE: Clean the transmission support insulator bolt using a wire brush and apply Motorcraft® Threadlock and Sealer to the threads.

   Install the transmission support insulator and install the transmission support insulator bolt and the transmission support insulator nuts.

   1. 1.
      
      Material

      : Motorcraft® Threadlock and Sealer / TA-25-B

      Torque

      : 111 lb.ft (150 Nm)

   1. 2.
      
      Material

      : Motorcraft® Threadlock and Sealer / TA-25-B

      Torque

      : 46 lb.ft (63 Nm)

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1. 15.
   
   Connect the transmission fluid cooler tubes to the transmission fluid cooler thermal bypass valve.

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1. 16.
   
   Install the transmission fluid cooler tube secondary latches.

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1. 17.
   
   Install the crankcase vent tube, connect the electrical connector and wiring harness retainer.

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1. 18.
   
   Install the CAC tube bolts.

   Torque

   : 53 lb.in (6 Nm)

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1. 19.
   
   Install the RH and LH cowl filler panels.

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1. 20.
   
   Position back the oil filter adaptor assembly and install the bolts.

   Torque

   : 18 lb.ft (25 Nm)

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1. 21.
   
   
   NOTE: Apply thread sealant before installing the oil pressure sensor.

   Install the oil pressure sensor.

   Material

   : Motorcraft® Threadlock and Sealer / TA-25-B

   Torque:

   Stage 1: 133 lb.in (15 Nm)

   Stage 2: 180°

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1. 22.
   
   Connect the oil control solenoid, oil pressure sensor and the wiring harness retainers.

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1. 23.
   
   
   NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.

   Install the new engine oil filter.

   Material

   : Motorcraft® SAE 5W-30 Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

   Torque:

   Stage 1: 71 lb.in (8 Nm)

   Stage 2: 180°

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1. 24.
   
   Install the stater motor insulator.

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1. 25.
   
   Install the starter motor. REFER to: Starter Motor .

1. 26.
   
   Connect the electrical connectors and the wiring harness retainers.

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1. 27.
   
   Inspect the halfshaft hub for wear or damage and install a new halfshaft, if necessary.

   1. 1.
      
      Inspect the differential seal surface.

   1. 2.
      
      Inspect the halfshaft bushing surface. If this surface is damaged, inspect the halfshaft bushing for damage.

   1. 3.
      
      Inspect the differential side gear splines.

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1. 28.
   
   Install the new inner halfshaft retaining circlip.

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1. 29.
   
   
   NOTE: If the transmission has been replaced or overhauled, the halfshaft seals do not need to be replaced.

   Install a new LH halfshaft seal. REFER to: Halfshaft Seal LH .

1. 30.
   
   Install the seal protector.

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1. 31.
   
   
   NOTE: Do not fully install shaft at this time.

   Using the seal protector, insert the splines of the halfshaft through the halfshaft seal and remove the seal protector.

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1. 32.
   
   
   NOTE: Insert shaft until circlip is fully seated. When checking if circlip is seated do not pull on CV joints or damage can result.
   NOTE: Pull on the inner CV joint to ensure the halfshaft circlip is seated properly.

   Insert the halfshaft until the halfshaft retaining clip is fully seated.

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Vehicles with all wheel drive (AWD) 

1. 33.
   
   Install the new PTU to transmission compression seal.

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1. 34.
   
   Install the PTU and the PTU bolts.

   Torque

   : 66 lb.ft (90 Nm)

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1. 35.
   
   Connect the PTU vent hose.

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1. 36.
   
   Install the PTU heat shield and the PTU heat shield bolts.

   Torque

   : 97 lb.in (11 Nm)

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1. 37.
   
   If equipped, connect the PTU temperature sensor. Connect the PTU sensor connector to the bracket.

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1. 38.
   
   Install the roll restrictor bracket and the roll restrictor bracket bolts.

   Torque

   : 66 lb.ft (90 Nm)

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1. 39.
   
   Install the turbocharger oil return line. REFER to: Turbocharger Oil Return Tube .

1. 40.
   
   Install the RH roll restrictor. REFER to: Roll Restrictor RH .

1. 41.
   
   Using the index mark, position the driveshaft and install the new driveshaft-to-PTU output flange bolts.

   Torque

   : 26 lb.ft (35 Nm)

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1. 42.
   
   Fill the PTU fluid. REFER to: Power Transfer Unit Fluid Level Check .

1. 43.
   
   Install the catalytic converter. REFER to: Catalytic Converter .

1. 44.
   
   

   1. 1.
      
      Inspect the inboard end of the RH halfshaft.

   1. 2.
      
      Inspect the dust shield.

   1. 3.
      
      Inspect the differential side gear splines.

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1. 45.
   
   

   1. 1.
      
      Inspect the outboard end of the RH halfshaft.

   1. 2.
      
      Inspect the halfshaft splines.

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1. 46.
   
   .

1. 47.
   
   
   NOTE: FWD shown in illustration AWD is similar.

   1. 1.
      
      
      NOTE: Do not fully install the shaft at this time.

      Install the seal protector.

   1. 2.
      
      Insert the halfshaft splines through the seal protector.

   1. 3.
      
      Remove the seal protector.

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1. 48.
   
   
   NOTE: FWD shown in illustration AWD is similar.

   Insert the intermediate shaft until the intermediate shaft bearing mounting bracket is seated to the intermediate shaft support bracket.

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1. 49.
   
   
   NOTE: FWD shown in illustration AWD is similar.

   Install the new halfshaft retaining nuts.

   Torque

   : 18 lb.ft (25 Nm)

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1. 50.
   
   Pull the halfshaft into the front wheel bearing and wheel hub.

   Use Special Service Tool: 204-161 (T97P-1175-A) Installer, Halfshaft.

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Vehicles with front wheel drive (FWD) 

1. 51.
   
   

   1. 1.
      
      Inspect the RH halfshaft seal surface.

   1. 2.
      
      Inspect the dust shield.

   1. 3.
      
      Inspect the differential side gear splines.

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1. 52.
   
   
   NOTE: If the transmission has been replaced or overhauled, the halfshaft seals do not need to be replaced.

   Install a new RH halfshaft seal. REFER to: Halfshaft Seal RH - FWD .

1. 53.
   
   Install the seal protector.

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1. 54.
   
   
   NOTE: Do not fully install the shaft at this time.

   1. 1.
      
      Insert the halfshaft splines through the seal protector.

   1. 2.
      
      Remove the seal protector.

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1. 55.
   
   Install the RH halfshaft assembly.

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1. 56.
   
   Install the new halfshaft retaining nuts.

   Torque

   : 18 lb.ft (25 Nm)

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1. 57.
   
   Install the catalytic converter bracket and the bolts.

   1. 1.
      
      Torque

      : 18 lb.ft (25 Nm)

   1. 2.
      
      Torque

      : 30 lb.ft (40 Nm)

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1. 58.
   
   If removed, clean the roll restrictor through bolts using a wire brush and apply Motorcraft® Threadlock and Sealer to the threads. Install the roll restrictor bracket and bolts.

   Material

   : Motorcraft® Threadlock and Sealer / TA-25-B

   Torque

   : 66 lb.ft (90 Nm)

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All vehicles 

1. 59.
   
   Connect the wiring harness retainers.

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1. 60.
   
   Install the front subframe. REFER to: Front Subframe .

Vehicles with all wheel drive (AWD) 

1. 61.
   
   
   NOTE: Do not tighten the front wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.
   NOTE: Install and tighten the new wheel hub nut to specification in a continuous rotation. Always install a new wheel hub nut after loosening or when not tightened to specification in a continuous rotation or damage to the components may occur.
   NOTE: Apply the brake to keep the halfshaft from rotating.

   While an assistant applies the brake, install the new wheel hub nut.

   Torque

   : 258 lb.ft (350 Nm)

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1. 62.
   
   Install the wheel and tire. REFER to: Wheel and Tire .

All vehicles 

1. 63.
   
   Connect the wiring harness retainers.

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1. 64.
   
   Install the selector lever cable bracket and the bolts.

   Torque

   : 18 lb.ft (25 Nm)

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1. 65.
   
   

   1. 1.
      
      
      NOTE: Lubricating the grommets with silicone grease will aid in the installation of the engine appearance cover, and any future removal and installation of the cover.

      Lubricate each grommet with silicone grease.

      Material

      : Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

   1. 2.
      
      Position the engine appearance cover onto engine with the grommets aligned with the studs.

   1. 3.
      
      Press down on the engine appearance cover at each grommet location to attach the grommets onto the studs.

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1. 66.
   
   Install the battery tray support bracket and bolt.

   Torque

   : 97 lb.in (11 Nm)

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1. 67.
   
   Install the following items:
   1. Refer to: Battery Tray .
   2. Refer to: Cowl Panel .

1. 68.
   
   Adjust the selector lever cable. REFER to: Selector Lever Cable Adjustment - 6-Speed Automatic Transmission - 6F35 .

1. 69.
   
   Fill the transmission with transmission fluid. REFER to: Transmission Fluid Drain and Refill .

1. 70.
   
   After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure using a diagnostic scan tool.

1. 71.
   
   If a new solenoid body is installed, the solenoid body strategy must be updated. REFER to: Transmission Strategy Download .