Installation
Transmission
Special Tool(s)
Material
Installation
All applications
1. Inspect the wiring harness and connectors for damage, condition of terminals, corrosion and seal integrity. Repair or install new as required.
2. Position, then raise the transmission into the vehicle.
^ WARNING: The torque converter must be held firmly in its installed position.
While holding the torque converter, carefully tilt the front of the transmission downward.
^ CAUTION: Do not allow the torque converter drive flats to disengage from the pump gear.
While continuing to hold the torque converter raise the transmission downward.
^ CAUTION: Watch for obstruction.
While continuing to hold the torque converter raise the transmission positioning the extension housing above the exhaust crossover pipe.
^ CAUTION: Watch for clearance between the transmission and engine and the transmission and exhaust crossover pipe.
Tilt the front of the transmission upward until level.
3. Remove the special tool.
4. CAUTION: Use care not to damage the flexplate and the converter pilot. The torque converter must rest squarely against the flexplate, indicating the converter pilot is not binding in the crankshaft.
Align the torque converter studs with the mounting holes in the flexplate. Install the transmission to the engine.
4.6L and 5.4L engines
5. Install and alternately tighten the torque converter housing-to-engine retaining bolts.
4.6L and 5.4L engines
6. Install four new torque converter nuts.
7. Install the flexplate inspection plate and the bolts. Install the rear engine plate-to-torque converter housing retaining bolt.
4.6L and 5.4L engines
8. Install the access plugs.
All applications
9. Connect the solenoid body connector.
10. Connect the output shaft speed (OSS) sensor connector.
11. Connect the digital TR sensor connector.
12. If so equipped, install the front A/C deflector assembly with the fasteners.
4.6L engines
13. Install the bracket onto the hanger and position it to the transmission insulator and retainer. Install the bolt.
All applications
14. Install the transmission support crossmember.
1. Install the transmission support crossmember onto the retainer and insulator studs. Install the retaining nuts hand-tight.
2. Raise the transmission, aligning the transmission support crossmember to the frame.
3. Install the stud brackets and the retaining nuts.
4. Tighten the retainer and insulator-to-crossmember retaining nuts.
15. Remove the high-lift transmission jack.
4.6L engines
16. Connect the catalyst monitoring sensor harness connectors.
17. Tighten the clamp.
All applications
18. Install the exhaust heat shield-to-crossmember retaining bolts.
All applications
19. Install the starter motor.
20. NOTE: The output shaft and the driveshaft are a balanced assembly.
Install the driveshaft.
^ Align the index marks and position the driveshaft on the transmission.
^ Position the driveshaft to the rear differential.
21. NOTE: To maintain initial driveshaft balance, align the index marks made during removal.
Install the driveshaft.
1. Install the driveshaft.
2. Install the bolts.
4.6L and 5.4L engines
22. Install the shift cable and bracket.
1. Install the bolts.
2. Connect the clip.
4.6L and 5.4L engines
23. NOTE: Prior to installation, check the condition of the transmission fluid filler tube O-ring. If damaged, install a new O-ring.
Install the fluid filler tube into the transmission. Position the retaining brackets. Install the bolt and nut.
All applications
24. With a drain pan correctly positioned, remove the plugs and connect the fluid cooler tubes.
4.6L and 5.4L engines
25. Install the bolts and position fuel line in place.
All applications
26. Connect the electrical harness connectors.
27. Use the following guidelines for the in-line transmission fluid filter:
^ If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a new in-line fluid filter.
^ If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter, install a new in-line fluid filter kit.
^ If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter kit.
^ If installing a new or a Ford authorized remanufactured transmission, install the in-line transmission fluid filter that is supplied.
Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit.
28. Install the engine cover.
29. Install the air cleaner air intake duct assembly.
30. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
Connect the battery ground cable.
31. Fill the transmission to the specified level with clean automatic transmission fluid.