Pages 17-09-45 Thru 17-09-50

1989
17-09-45 E40D Automatic Transmission 17-09-45




REMOVAL AND INSTALLATION (Continued)

23. Remove transmission cooling lines using a 1/2- inch flare wrench, from transmission case. Cap cooling lines and plug fittings at transmission.




24. Remove six bell housing bolts using a 5/8-inch socket.
25. Back out converter pilot form flywheel and gently lower transmission while observing hardware obstructions.




26. Install Torque Converter Handles, T81P- 7902-C or equivalent, on converter with handles in the 6 and 12 o'clock positions.

27. Remove transmission filler tube.

28. On 4 x 4 models only, remove transfer case vent hose form detent bracket. Refer to Section 16-80 or 16-81 for vent hose location, 29. On 4 x 4 models only, remove the transfer case from the transmission. Refer to Section 16-30 or 16-81 for transfer case removal procedures.

30. On F-Super Duty Models, remove the transmission mounted parking brake. Refer to Section 12-70 for procedure.




Installation Before installing transmission, check wiring harness for damage. Check connectors for electrical integrity (terminal condition, corrosion and contamination). Repair or replace as required.

1. Place transmission onto E40D Transmission Stand Fixture Rotunda Equipment Model 014- 4-763 or equivalent, 2. On 4 x 4 models only, install transfer case to transmission. Refer to Section 16-80 or 16-81 for transfer case installation procedures. On F-Super Duty Models, install transmission mounted parking brake. Refer to Section 12-70 for procedure.

3. Install torque converter using Torque Converter Handles T81P-7902-C or equivalent. Carry converter with the handles in the 6 and 12 o'clock positions. Push and rotate the converter onto the pump until it bottoms out.
NOTE: The torque converter must be installed with care, so as to reduce stator support Teflon seal damage. Check the seating of the converter by placing a straightedge across the bell housing. There must be a gap between the converter pilot and the straightedge.

1989
17-09-46 E40D Automatic Transmission 17-09-46




REMOVAL AND INSTALLATION (Continued)

4. Remove converter handles.
5. Check condition of filler tube O-ring, replace if damaged. Install filler tube.
6. Rotate converter studs to align with flywheel mounting holes.
7. Place bolts into bell housing mounting holes.
8. Raise transmission into position while observing all hardware obstructions. Do not allow converter drive flats to disengage from pump gear. Use rubber converter plug cover to aid in the alignment of the converter studs. Use care not to damage the flywheel and converter pilot. The converter must rest squarely against the flywheel. This indicates that the converter pilot is not binding in the engine crankshaft.




9. Alternately snug-up bell housing bolts using a 5/8-inch socket. Alternately tighten bell housing bolts to 55-67 N-m (40-50 ft.lbs).




10. Install rubber converter drain plug cover.

11. Install transmission cooling lines to transmission fittings using a 1/2-inch crows foot. Tighten to 24-31 N-m (18-23 ft.lbs).

12. Install crossmember and transmission retaining bolts.




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 converter studs. Install new stud nuts using 9/16-inch socket. Tighten to 28-40 N-m (20-30 ft.lbs).




15. Install starter motor. Refer to Section 28-02, Positive Engagement Starter in the Light Truck Engine Manual (Volume B) for starter removal and installation procedures.

16. Install rear engine plate cover and lower dust cover bolts using a 10 mm socket. Tighten to 17-21 N-m (12-16 ft.lbs).

1989
17-09-47 E40D Automatic Transmission 17-09-47





REMOVAL AND INSTALLATION (Continued)

1989
17-09-48 E40D Automatic Transmission 17-09-48




REMOVAL AND INSTALLATION (Continued)

17. Install speedometer cable. Refer to Section 33-02, Speedometer, for cable removal and installation procedures.

18. Completely seat solenoid body connector into solenoid valve body recepticle. An audible click indicates full contact.

NOTE: Seating the solenoid body connector should be done by simply pushing on the connector top until an audible click is heard. Do NOT push or pull on any of the connector tabs. Connector tabs used in disassembly only.




19. Install solenoid body connector heat shield with off-set bending inward. Tighten to 8-12 N-m (6-9 ft.lbs).




20. Install new wire harness locators into cross member.

21. Install wire harness locator into extension housing wire bracket.

22. On 4 x 4 models only, install four-wheel drive switch connector.

23. On 4 x 4 models only, connect transfer case shift linkage. Refer to Section 16-81, BorgWarner 13-56 Transfer Case-Manual Shift for procedure.

24. Install manual lever position sensor connector. An audible click indicates full connection.

NOTE: When the wiring harness is removed, the "Christmas Tree" locators must be replaced with new 13A506 wire retainers, before reinstalling the harness.

25. Install shift linkage. Refer to Section 17-02, Shift Control Linkage, for procedure.

26. On 4 x 4 models only, install shift rod to transfer case shift lever. Refer to Section 16-81, BorgWarner 13-56 Transfer Case Manual Shift, for procedure.

27. Install rear driveshaft. Refer to Section 15-61, Driveshaft-Single Type U-Joint, for removal procedure.

28. On 4 x 4 models only, install front driveshaft. Refer to Section 15-67, Front Driveshaft, for installation procedures.

29. Lower vehicle.

30. Connect negative battery cable.

31. Fill the transmission to the proper level with Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid part no. E4AZ- 19582-B, Specification ESP-M2C166-H) or equivalent.

1989
17-09-49 E40D Automatic Transmission 17-09-49




IN VEHICLE SERVICE

Extension Housing Gasket Removal
1. Position vehicle on a hoist.
2. Remove front (4 x 4 only) and rear driveshaft. Refer to Sections 15-67, Front Driveshaft and Section 15-61, Driveshaft-Single Type U-Joint, for removal procedures.
3. Remove transmission mounting pad nuts and bolts. Refer to the transmission removal procedures for crossmember illustrations.
4. On 4 x 4 models only, remove shift linkage from transfer case shift lever. Refer to the appropriate Sections in Group 16 for transfer case shift linkage removal and installation procedures.
5. On 4 x 4 models only, remove four-wheel drive switch connector from transfer case, use care not to overextend tabs.
6. Pry wire harness locators from extension housing wire bracket.
7. On 4 x 4 models only, remove wire harness locators from LH side of crossmember.
8. Remove speedometer cable. Refer to Section 33-02, Speedometer, for Cable Removal and Installation procedures.
9. On 4 x 4 models only, remove transfer case vent hose from detent place. Refer to the appropriate transfer case section in Group 16 for vent hose location.
10. On 4 x 4 models only, place Transmission Stand Fixture Rotunda Equipment Model No. 014- 00104 or equivalent on universal high lift transmission lack and position under transfer case.
11. Remove nine extension housing bolts using a 13 mm box wrench.

12. Slide transfer case rearward and downward to remove, and discard extension housing gasket from housing and transfer case mating surfaces.




Installation
1. Grease extension housing gasket and position on extension housing.

NOTE: Care should be taken to ensure that the parking pawl return spring is properly located on the inside surface of the case, when installing the extension housing. This spring must NOT be trapped in the sealing surfaces between the extension and case.




2. Raise extension housing into position.
3. Install nine extension housing bolts using a 13 mm socket. Tighten to 27-39 N-m (20-29 ft.lbs).

1989
17-09-50 E40D Automatic Transmission 17-09-50

IN VEHICLE SERVICE (Continued)

4. On 4 x 4 models only, attach transfer case vent hose to detent plate. Refer to the appropriate section in Group 16 for vent hose location.

5. On 4 x 4 models only, install four-wheel drive connector.

6. Install wire harness locator into extension housing wire bracket.

7. Install transmission mounting pad bolts and nuts and tighten to 81-108 N-m (60-80 ft.lbs) for all F Series or 68-96 N-m (50-70 ft.lbs) for all E Series.

8. Remove universal high lift transmission jack.

9. Install speedometer cable. Refer to Section 33-02, Speedometer, for Cable Removal and Installation procedures.

10. Install front (4 x 4 only) and rear driveshaft. Refer to Section 15-67, Front Driveshaft and Section 15-61, Driveshaft-Single Type U-Joint for removal procedures.

11. Fill the transmission to the proper level with Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid, part no. E4AZ- 19582-B, specification (ESP-M2C166-H) or equivalent.




Parking Mechanism Follow extension housing gasket replacement procedure for removal and installation of extension housing.

Removal
1. Remove two bolts using a 13 mm socket from park rod guide plate.

2. Remove parking pawl return spring, pin and parking pawl from case.





3. Remove the Torx head bolt (40A bit) and parking pawl abutment.




Installation

1. Install parking pawl, pin and return spring.

NOTE: Spring end rests on inside surface of case.

2. Install parking pawl abutment with Torx head bolt (40A bit). Tighten to 22-27 N-m (16-20 ft.lbs).