Installation

Transmission - Four Wheel Drive (4WD)





1. WARNING: Secure the assembly to the jack. Avoid any obstructions while lowering and raising the jack. Contact with obstructions may cause the assembly to fall off the jack, which may result in serious personal injury.

If removed, install the transfer case to the back of the transmission. Install the transfer case bolts, bracket and connect the vent hose.
- Tighten to 41 Nm (30 lb-ft).





2. NOTE: Rotate the torque converter so that the torque converter paint mark is in the 12 o'clock position.

Install the Torque Converter Retainer if not done during assembly.





3. Raise and position the transmission and transfer case to the back of the engine.

4. Remove the Torque Converter Retainer.





5. Position the fuel line bracket in place and install the 6 transmission-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).





6. NOTICE: Rotating the crankshaft pulley bolt counterclockwise could cause a reduction in clamp load on the crankshaft pulley and timing sprocket, which could cause severe engine damage.

Install 4 new torque converter-to-flexplate nuts.

- Tighten to 44 Nm (32 lb-ft).





7. Install the starter motor and starter motor bolts.
- Tighten to 25 Nm (18 lb-ft).





8. Install the ground cable and ground cable nut.
- Tighten to 13 Nm (115 lb-in).





9. Install the lower transmission-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).





10. Install a jackstand under the transfer case.





11. Remove the transmission jack from under the transmission.

12. NOTICE: Use care not to bend or force the transmission fluid cooler tubes, otherwise damage to the transmission fluid cooler tubes and the transmission may result.

NOTE: Hold the transmission case fittings with a backup wrench.

Install the transmission fluid cooler tubes nut-to-case fitting.

- Tighten to 40 Nm (30 lb-ft).





13. Connect the Transmission Range (TR) sensor connector.





14. Move the TR sensor boot back over the TR sensor connector.





15. Position the wire harness and install the retainers.





16. Attach the LH Heated Oxygen Sensor (HO2S) to the transmission and install the wire harness retainer.





17. NOTICE: Damage will occur to the transmission control solenoid body assembly if the screw is tightened above the specification.

NOTE: Always install new O-ring seals on the transmission vehicle harness connector.

NOTE: Clean the area around transmission vehicle harness connector to prevent contamination of the transmission vehicle harness connector.

NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.

Install and lubricate new O-ring seals on the transmission vehicle harness connector and connect the transmission vehicle harness connector.
- Tighten to 5 Nm (44 lb-in).





18. Attach the LH Catalyst Monitor Sensor (CMS) connector to the transmission.





19. Attach the RH HO2S to the transmission.





20. Attach the fuel lines and the RH CMS connector to the bracket.





21. Connect the Turbine Shaft Speed (TSS) sensor, Output Shaft Speed (OSS) sensor and intermediate shaft speed sensor connectors.





22. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket.

NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever. Pull back on the selector lever cable end to make sure that the selector cable end is securely installed onto the manual control lever.

Install the selector lever cable end onto the manual control lever, selector lever cable bracket and selector lever cable bracket screws.

- Tighten to 40 Nm (30 lb-ft).





23. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield.

Install the selector lever cable shield.





24. NOTE: LH side shown, RH similar.

If removed, install the transmission support insulator and transmission support insulator screws.

- Tighten to 90 Nm (66 lb-ft).





25. NOTICE: Prior to Installation, Inspect the HO2S and the CMS wiring harness for damage.

NOTE: RH side shown, LH side similar.

NOTE: This step may require an assistant.

Position the catalytic converter assembly and loosely install the 4 catalytic converter-to-manifold nuts.





26. NOTE: LH side shown, RH side similar.

Connect the 2 HO2S connectors.





27. NOTE: LH side shown, RH side similar.

Connect the 2 CMS sensor connectors.





28. Position the crossmember in place and loosely install the 2 transmission support insulator-to-crossmember nuts to support the crossmember.





29. Install the 4 RH side crossmember bolts and the nut.
- Tighten to 70 Nm (52 lb-ft).





30. Install the 4 LH side crossmember bolts and the nut.
- Tighten to 70 Nm (52 lb-ft).





31. Remove the jackstand.





32. Tighten the transmission support insulator-to-crossmember nuts.
- Tighten to 90 Nm (66 lb-ft).





33. Install the LH exhaust heat shield bolts.
- Tighten to 20 Nm (177 lb-in).





34. If equipped, install the RH exhaust heat shield.
- Tighten to 20 Nm (177 lb-in).





35. NOTE: RH shown, LH similar.

Tighten the 4 catalytic converter-to-manifold nuts.

- Tighten to 40 Nm (30 lb-ft).





36. Using a new gasket, install the catalytic converter-to-muffler pipe and the heat shield. Install the catalytic converter-to-muffler pipe bolts, springs and flagnuts.
- Tighten to 40 Nm (30 lb-ft).





37. If equipped, connect the 4WD shift motor connector.





38. Install the driveshafts. For additional information, refer to Drive/Propeller Shafts, Bearings and Joints.

39. Use the following guidelines for installing the in-line transmission fluid filter:
- If the transmission was overhauled and the vehicle was equipped with an in-line transmission fluid filter, install a new in-line transmission fluid filter.

- If the transmission was overhauled and the vehicle was not equipped with an in-line transmission fluid filter, install a new in-line transmission fluid filter kit.

- If the transmission is being installed for a non-internal repair, do not install an in-line transmission filter or filter kit.

- If installing a new or a Ford-authorized remanufactured transmission, install a new in-line transmission fluid filter.
- Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit.

40. If equipped, position the skid plate and install the 4 skid plate bolts.
- Tighten to 24 Nm (18 lb-ft).





41. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they can experience slightly different upshifts (either soft or firm) and that this is a temporary condition and will eventually return to normal operating condition.

Connect the battery ground cable.

42. Position the cooling fan shroud and install the bolts.
- Tighten to 7 Nm (62 lb-in).

43. Position the coolant expansion tank and install the bolts.
- Tighten to 7 Nm (62 lb-in).

44. Carry out the fluid level check. For additional information, refer to Transmission Fluid Level Check Transmission Fluid Level Check.

45. Verify that the selector lever cable is correctly adjusted. For additional information, refer to Automatic Transmission/Transaxle.

46. Check the operation of the transmission and inspect for leaks.