E4OD
Transmission
SPECIAL SERVICE TOOL(S) REQUIRED
Removal
1. Disconnect battery ground cable (14301) at the battery.
2. Remove transmission oil level indicator.
3. Place transmission gearshift selector lever in NEUTRAL position.
4. Raise vehicle on a hoist and position suitable safety stands under vehicle.
5. Remove skid plate (4x4 vehicles).
6. On 4x4 models only. remove front driveshaft. Drive Axles, Bearings and Joints
7. Remove rear driveshaft. Drive Axles, Bearings and JointsOn F-Super Duty vehicles, remove the transmission-mounted parking brake.
8. Disconnect shift cable, or linkage on F-Super Duty Motorhome and Commercial vehicles. Shift Linkage
9. On 4x4 models only, (mechanical shift systems) remove shift linkage from transfer case shift lever. Disconnect connector at transfer case.
CAUTION: Do not attempt to pry tabs with pry bar or screwdriver.
10. Remove manual lever position sensor connector by squeezing connector tabs and pulling on connector.
11. Remove muffler (5230) and tail pipe assembly (5.8L Lightning Truck applications only). On 7.3L DI Turbo Diesel, remove exhaust crossover.
12. Remove nuts retaining three-way catalytic convener (5E212) to exhaust manifolds (9430) (5.8L Lightning Truck application only) and let assembly rest on frame (5005).
13. To remove solenoid body connector transmission heat shield loosen two bolts using an 8mm wrench. Remove transmission heat shield.
CAUTION: Do not attempt to pry tab with pry bar or screwdriver.
14. Remove solenoid body connector carefully by pushing on the center tab end pulling on the wire harness.
15. On 4x4 models only, remove four-wheel drive switch connector from transfer case, Use care not to over extend tabs.
16 Carefully pry wire harness locator from extension housing wire bracket.
17. On 4x4 models only remove wire harness locators from left side of rear engine support (6A023).
18. Remove lower torque convener cover bolts using a 1O mm socket and remove cover.
19. Remove rear engine cover plate bolts
20. Remove starter. Starting System
21. Remove access hole rubber plug Use a 15/16 inch socket to rotate crankshaft (6202) to gain access to the converter drain plug. Remove plug Drain torque Converter.
22. Rotate crankshaft bolt to gain access to converter nuts. Using a 9/16 inch socket, remove four converter mounting nuts and discard.
23. Place Rotunda E40D Transmission Adapter 014-00763 or equivalent on universal transmission jack and position adapter as in following illustration.
Placement of Positioning Pins
24. Use a safety strap to secure transmission.
NOTE: Transmission may have to be raised to gain adequate clearance to remove rear engine support.
25. Remove the two rear transmission mounting pad nuts using an 18mm socket. Remove crossmember- to-frame bolts and remove rear engine support from transmission.
Crossmember Installation, E- and F-Series Vehicles.
NOTE:Case connector fitting should be held with wrench to prevent it from moving when loosening tube nut.
26. Remove transmission oil cooler tubes using a 1/2-inch flare nut wrench from transmission case. Cap transmission oil cooler tubes and plug fittings at transmission. The F-Super Duty Motorhome Chassis requires the use of a 5/8-inch tube nut wrench.
27. Remove four torque converter housing bolts.
28. Shift transmission to the left and remove three-way catalytic converter from vehicle (5.8L Lightning Truck applications only).
29. Back out transmission assembly from flywheel and gently lower while watching for any obstructions.
CAUTION: Torque converter is very heavy.
NOTE: Fluid loss will occur when torque converter is removed.
30. Install Torque Converter Handles T81P-7902-C on torque converter with handles in the 6 and 12 o'clock positions. Carefully remove torque converter from transmission by pulling evenly on handles.
31. Remove transmission Oil filler tube from lube oil inlet short tube
32. On 4x4 models only, remove transfer case vent hose from detent bracket.
33. On 4x4 models only, remove the transfer case from the transmission. Service and Repair.
Installation
Transmission
Before installing transmission, check wiring harness for damage. Check connectors for electrical integrity (terminal condition, corrosion, contamination and seal integrity). Repair or replace as required.
1. Place transmission onto E4OD Transmission Adapter 014-00763 or equivalent.
2. On 4x4 models only, install transfer case to transmission. Service and Repair. On F-Super Duty Models, install transmission mounted parking brake. Service and Repair
CAUTION: Use care when installing torque converter to avoid damage to the stator support Teflon� seal.
NOTE: Check the converter crankshaft pilot for nicks or damaged surfaces that could cause interference when installing the transmission to engine. Check the converter impeller hub for nicks or sharp edges that would damage the pump seal.
3. Install torque converter using Torque Converter Handles T81P-7902-C. Carry torque converter with the handles in the 6 and 12 o'clock positions. Push and rotate the torque converter onto the pump until it bottoms Out.
. Check the seating of the torque convener by placing a straightedge across the converter housing. There must be a gap between the converter pilot face and the straightedge.
4. Remove converter handles.
5. Check condition of oil filler tube 0-ring, replace it damaged. Install oil filler tube.
6. Rotate torque converter Studs to align with flywheel mounting holes.
7. Raise transmission into position while watching for any obstructions. Do not allow torque converter drive flats to disengage from pump gear. Rubber converter drain plug cover may be removed to aid in the alignment of the converter studs. Use care not to damage the flywheel and converter pilot. The torque converter must rest squarely against the flywheel This indicates that the torque converter pilot is not binding in the engine crankshaft.
8. Install transmission-to-engine bolts. Alternately tighten bolts using a 5/8 inch socket. Alternately tighten bolts to 51-70 Nm (38-52 ft-lb) for gas engine applications, or to 86-90 N.m (63-66 ft-lb) for diesel engine applications.
9. Install rubber converter drain plug cover, if removed.
10. Shift transmission to the left and position three-may catalytic converter to the exhaust manifolds (5.8L Lightning Truck applications only). Exhaust System
NOTE:Case connector fitting should be held with wrench to prevent it from moving when tightening tube nut.
11. Install transmission Oil cooler tubes to transmission fittings. Tighten to 24-31 Nm (18-23 ft-lb) on all applications except F-Super Duty vehicles. Tighten transmission oil cooler tube fittings to 24-31 Nm (18-23 ft-lb) for F-Super Duty applications.
12. Install rear engine support and transmissi0n retaining bolts. Make sure that wiring harness is properly routed.
13. Remove safety strap and universal high lift transmission jack.
14. Rotate crankshaft using a 15/16-inch socket on front pulley bolt to gain access to torque convener studs. Install new stud nuts using 9/16-inch socket. Tighten to 34-46 Nm (25-34 ft-lb).
15 Install starter motor (11001). Starting System
16. Install rear engine plate cover and lower dust cover bolts. Tighten to specifications indicated in specifications, in this section.
Specifications
Crossmember Installation, E- and F-Series Vehicles
17. Completely seat solenoid body connector into solenoid valve body receptacle by pushing on the top of the connector. An audible click indicates full contact. Verify connection by pulling on harness.
18. Install solenoid body connector transmission heat shield with off-set bending inward. Tighten to 9-11 Nm (80-100 in-lb).
19. On 4x4 models only, install new harness locations into rear engine support.
20. Install new wire harness locator into extension housing wire bracket.
21. Install four-wheel drive switch connector, if equipped.
22. Connect transfer case shift linkage, if equipped.
23. Install manual lever position switch connector. As audible click indicates full connection.
24. Install shift cable, or linkage on F-Super Duty Motorhome and Commercial vehicles. Shift Linkage
25. Install parking brake cable (F-Super Duty).
26. Install muffler and tailpipe and crossover assembly. (5.8L Lightning Truck and 7.3L DI Diesel applications only). Exhaust System
27 Install rear driveshaft. Drive Axles, Bearings and Joints
28. On 4x4 models only, install front driveshaft. Drive Axles, Bearings and Joints
29. Remove safety stands and lower vehicle.
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 10 miles or more to relearn the strategy.
30. Connect battery ground cable.
31. Fill the transmission to the proper level with Motorcraft MERCON� V Multi-Purpose Automatic Transmission Fluid (E4AZ-19582-B) or equivalent. Refer to Fluid Capacity Chart under specifications Specifications