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Transmission - 4x4: Installation

  1. Install the special tool.
    Fig 1: Installing Special Tool
    G03929232Courtesy of FORD MOTOR CO.
    2. CAUTION: The 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 converter pilot is not binding in the engine crankshaft.
  2. Position and secure the transmission on the high-lift transmission jack. Raise and position the transmission into the vehicle.
    3. NOTE: Make sure the torque converter is fully seated in the transmission before aligning the transmission to the engine.
  3. With the transmission in a horizontal position move it toward the engine. Align the orange balancing marks between the torque converter studs and the flexplate bolt holes.
    4. NOTE: Install the transmission bolts in their correct locations noted during removal.
    Fig 2: Installing Transmission-To-Engine Bolts
    G03929231Courtesy of FORD MOTOR CO.
  4. Install the 7 transmission-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
  5. Install the front sway bar U-brackets and the bolts.
    • Tighten to 102 Nm (75 lb-ft).
    Fig 3: Installing Front Sway Bar U-Brackets And Bolts
    G03929464Courtesy of FORD MOTOR CO.
  6. Connect the wire harness retainer to the top of the transmission. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place.
    Fig 4: Connecting Wire Harness Retainer
    G03929229Courtesy of FORD MOTOR CO.
  7. Connect the wire harness to the top of the transmission.
    Fig 5: Connecting Wire Harness To Top Of Transmission
    G03929228Courtesy of FORD MOTOR CO.
  8. Connect the RH heated oxygen sensor (HO2S) electrical connector to the side of the transmission.
    Fig 6: Connecting RH Heated Oxygen Sensor
    G03929227Courtesy of FORD MOTOR CO.
  9. Connect the LH HO2S electrical connector to the side of the transmission.
    Fig 7: Connecting LH HO2S Electrical Connector
    G03929226Courtesy of FORD MOTOR CO.
  10. Install the rear transmission mount. Install the LH bolt for the rear transmission support.
    • Tighten to 80 Nm (59 lb-ft).
    Fig 8: Installing Rear Transmission Mount
    G03929225Courtesy of FORD MOTOR CO.
  11. Install the RH bolt for the rear transmission support.
    • Tighten to 80 Nm (59 lb-ft).
    Fig 9: Installing RH Bolt
    G03929224Courtesy of FORD MOTOR CO.
  12. Install the exhaust hanger.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 10: Installing Exhaust Hanger
    G03929223Courtesy of FORD MOTOR CO.
  13. Position the rear crossmember in place and loosely install the transmission retaining nuts.
    Fig 11: Installing Transmission Retaining Nuts
    G03929222Courtesy of FORD MOTOR CO.
  14. Install the bolts for the rear crossmember.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 12: Installing Rear Crossmember Bolts
    G03929221Courtesy of FORD MOTOR CO.
  15. Tighten the 2 rear transmission nuts.
    • Tighten to 103 Nm (76 lb-ft).
    Fig 13: Tightening Rear Transmission Nuts
    G03929474Courtesy of FORD MOTOR CO.
  16. Install the RH exhaust heat shield bolt.
    • Tighten to 15 Nm (11 lb-ft).
    Fig 14: Installing RH Exhaust Heat Shield Bolt
    G03929219Courtesy of FORD MOTOR CO.
  17. Install the LH exhaust heat shield bolt.
    • Tighten to 15 Nm (11 lb-ft).
    Fig 15: Installing LH Exhaust Heat Shield Bolt
    G03929220Courtesy of FORD MOTOR CO.
  18. Connect the transmission fluid cooler tubes.
    Fig 16: Connecting Transmission Fluid Cooler Tubes
    G03929217Courtesy of FORD MOTOR CO.
  19. Install the transmission fluid cooler tube bracket and the nut.
    • Tighten to 27 Nm (20 lb-ft).
    Fig 17: Identifying Transmission Fluid Cooler Tube Bracket & Nut
    G03929218Courtesy of FORD MOTOR CO.
  20. Connect the engine oil level sensor electrical connector.
    Fig 18: Connecting Engine Oil Level Sensor Electrical Connector
    G03929216Courtesy of FORD MOTOR CO.
  21. Install the transmission fluid cooler tube retainer and the bolt.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 19: Installing Transmission Fluid Cooler Tube Retainer
    G03929215Courtesy of FORD MOTOR CO.
    22. NOTE: Inspect the case to make sure that the old band seals and backer rings are not stuck in the case.
    NOTE: Install new band seals and backer rings on the ends of the cooler tubes prior to installing.
    Fig 20: Installing New Seals
    G03929481Courtesy of FORD MOTOR CO.
  22. Install new seals on the transmission fluid cooler tubes.
    1. Transmission fluid cooler tube.
    2. Retainer plate.
    3. Backer ring.
    4. Band seal.
    23. NOTE: Inspect the case to make sure that the old band seals and backer rings are not stuck in the case.
    NOTE: Install new band seals and backer rings on the ends of the cooler tubes prior to installing.
    Fig 21: Installing Transmission Cooler Tube Retainer Bolt
    G03929214Courtesy of FORD MOTOR CO.
  23. Position the fluid cooler tubes into the transmission, then install the bolt for the transmission cooler tube retainer.
    • Tighten to 23 Nm (17 lb-ft).
  24. Install the starter motor and the 3 bolts.
    • Tighten to 26 Nm (19 lb-ft).
    Fig 22: Installing Starter Motor
    G03929213Courtesy of FORD MOTOR CO.
  25. Install the ground wire to the stud.
    • Tighten to 23 Nm (17 lb-ft).
    Fig 23: Installing Ground Wire
    G03929212Courtesy of FORD MOTOR CO.
  26. Install the starter motor electrical connectors.
    1. Tighten to 12 Nm (9 lb-ft).
    2. Tighten to 6 Nm (53 lb-in).
    Fig 24: Installing Starter Motor Electrical Connectors
    G03929485Courtesy of FORD MOTOR CO.
  27. Install the plastic starter motor electrical connector cap.
    Fig 25: Installing Plastic Starter Motor Electrical Connector Cap
    G03929210Courtesy of FORD MOTOR CO.
  28. Install 4 new torque converter nuts.
    • Rotate the crankshaft to access all the torque converter nuts.
    • Tighten to 35 Nm (26 lb-ft).
    Fig 26: Locating Bolt
    G03929208Courtesy of FORD MOTOR CO.
  29. Install the rubber access plug.
    Fig 27: Installing Rubber Access Plug
    G03929207Courtesy of FORD MOTOR CO.
  30. Install the flexplate inspection cover.
    • Tighten to 35 Nm (26 lb-ft).
    Fig 28: Installing Flexplate Inspection Cover
    G03929205Courtesy of FORD MOTOR CO.
  31. Install the RH engine-to-transmission support bracket and the bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 29: Installing RH Engine-To-Transmission Support Bracket
    G03929490Courtesy of FORD MOTOR CO.
  32. Install the LH engine-to-transmission support bracket and the bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 30: Installing LH Engine-To-Transmission Support Bracket
    G03929206Courtesy of FORD MOTOR CO.
  33. Install the shift cable bracket bolts and connect the shift cable end.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 31: Locating Shift Cable Bracket Bolts
    G03929171Courtesy of FORD MOTOR CO.
  34. Install the transfer case. For additional information, refer to TRANSFER CASE - AUTOMATIC SHIFT .
    35. NOTE: 4x2 shown, 4x4 similar.
    Fig 32: Installing Fuel Line Bracket & Bolt
    G03929203Courtesy of FORD MOTOR CO.
  35. Install the fuel line bracket and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
  36. Connect the battery ground cable.
    37. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields.
    Fig 33: Locating Fill Plug
    G03929125Courtesy of FORD MOTOR CO.
  37. Remove the fluid fill plug.
    • The fill plug is located on the RH rear side of the case near the transmission electrical connector.
    38. CAUTION: The use of any other transmission fluid than specified, can result in the transmission failing to operate correctly or transmission failure.
    Fig 34: Locating Fluid Fill Plug
    G03929126Courtesy of FORD MOTOR CO.
  38. Fill the transmission.
    • Add 4.7 liters (5 quarts) of clean automatic transmission fluid to the transmission through the fluid fill hole. Stop when the fluid runs out of the bottom of the hole.
  39. Install the fluid fill plug.
    • Tighten to 35 Nm (26 lb-ft).
    Fig 35: Installing Fill Plug
    G03929125Courtesy of FORD MOTOR CO.
  40. Verify that the shift cable is correctly adjusted. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS .
  41. Reflash the transmission control module (TCM) to the latest level of software.
  42. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements.
  43. With the engine idling (600-750 rpm) in PARK and the transmission temperature at 30°C-50°C (86°F-122°F), check and adjust the transmission fluid level.
    44. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields.
    Fig 36: Locating Fluid Fill Plug
    G03929126Courtesy of FORD MOTOR CO.
  44. With the engine still running in PARK, check the fluid level. If more fluid is needed, remove the fluid fill plug on the side of the case and fill with clean automatic transmission fluid until the fluid runs out of the bottom of the hole.
  45. Install the fluid fill plug.
    • Tighten to 35 Nm (26 lb-ft).
    Fig 37: Installing Fill Plug
    G03929125Courtesy of FORD MOTOR CO.
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