Installation

1. Inspect the wiring harness and the connectors for damage, terminal condition, corrosion and seal integrity. Repair or replace as required.
2. Lubricate the torque converter pilot hub.
- Use Ford Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specification ESA-M1C45-A.

CAUTION: Prior to installation of the transmission assembly, the torque converter pilot hub must be properly lubricated.





3. Position, then raise the transmission into the vehicle.

CAUTION: Watch for obstructions.





4. Align the (A) torque converter studs with the mounting holes in the (B) flywheel. Install the (C) transmission to the (D) engine.

CAUTION: Do not allow the torque converter drive flats to disengage from the pump gear. Use care not to damage the flywheel and the converter pilot. The torque converter must rest squarely against the flywheel, indicating the converter pilot is not binding in the crankshaft.

NOTE: The torque converter drain plug cover can be removed to aid in the alignment of the converter studs.





5. Install and alternately snug the 4 transmission-to-engine retaining bolts.





6. Install the 4 new torque converter-to-flywheel retaining nuts.
(1) Rotate the (A) crankshaft pulley-to-crankshaft retaining bolt to position the (B) torque converter stud in the center of the (C) cylinder block opening.
(2) Install the new torque converter-to-flywheel retaining nut.
- Repeat substeps 1 and 2 for each of the remaining torque converter-to-flywheel retaining nuts.





7. Alternately tighten the 4 transmission-to-engine retaining bolts.





8. Install the cylinder block opening cover.





9. With a drain pan properly positioned, remove the plugs and connect the fluid cooler tubes to the CBV.
10. Install the exhaust heat shields and the exhaust crossover pipe.





11. Install the transmission support crossmember.
(1) Lower the transmission, as necessary, to install the (A) transmission support crossmember onto the (B) retainer and insulator studs. Install the (C) retaining nuts hand-tight.
(2) Raise the transmission, aligning the (A) transmission support crossmember to the (D) frame.
(3) Install the (E) stud brackets and the (F) retaining nuts hand-tight.
(4) Tighten the crossmember-to-frame retaining nuts.
(5) Tighten the retainer and insulator-to-crossmember retaining nuts.





12. Remove the (A) Highlift Transmission Jack with the (B) E40D Transmission Jack Adapter from the (C) transmission.





13. Reinstall the 3 transmission fluid pan-to-case retaining bolts removed to install the jack adapter.





14. Install the exhaust heat shield-to-crossmember retaining bolts.





15. Install the (A) flywheel inspection plate and the (B) bolts.





16. If so equipped, install the (A) front A/C deflector assembly with the (B) fasteners.
17. Install the starter motor.
18. Install the transmission-mounted parking brake assembly (if so equipped).
19. Install the driveshaft.
20. Install the shift cable.
21. Remove the supports and lower the vehicle.





22. Position the (A) fuel and electrical harness bracket for installation. Install and alternately snug, then tighten, the (B) transmission-to-engine retaining bolts.





23. Connect the electrical harness connectors.





24. Install the transmission fluid filler tube.
(1) Install the (A) fluid filler tube into the (B) short fluid inlet tube.
(2) Position the (C) retaining bracket onto the stud and install the (D) nut hand-tight.
(3) Install the bolt.
(4) Tighten the fluid filler tube-to-cylinder head retaining nut.

NOTE: Prior to installation, check the condition of the transmission fluid filler tube O-ring. Replace it if damaged.





25. Position the (A) vapor management valve assembly to the (B) cowl. Install the (C) nuts.
26. Install the engine cover.
27. Install the air cleaner air intake duct assembly.
28. Connect the battery.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

29. Fill the transmission to the proper level with MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent.