Removal and Installation

REMOVAL AND INSTALLATION
Transmission (4x2)
Removal

1. Shift the transmission into neutral.

Floor Carpet/Mat F150-F-350, Super duty Chassis Cab and Bronco

2. Remove the carpet or floor mat.






A. Remove the seats
B. Grasp the carpet or mat surrounding edge beneath the convoluted floor shifter and pull it outward and upward away from the boot.
C. Remove the floor console.
D. Remove the screws retaining the RH and LH cowl side trim panels.
E. Remove all carpet or mat retaining screws.
3. Remove the shifter boot retainer screws and slide the boot up the shift lever shaft.
4. Remove the shift lever retaining bolt and remove the shift lever.
5. Raise the vehicle on a hoist and position safety stands under the vehicle.
6. Disconnect the speedometer cable.
7. Disconnect the back-up lamp switch located at the top left hand side of the transmission.
8. Remove the drain plug and drain the oil from the transmission.
9. Position a transmission jack, such as Rotunda Transmission Jack 077-00008 or equivalent under the transmission.
10. Remove the driveshaft from the transmission.
11. Disconnect the clutch slave cylinder hydraulic line. Hydraulic Hose






12. Remove the transmission rear insulator and lower retainer.
13. Remove the bolts that retain the transmission to the engine block.
14. Move the transmission to the rear until the input shaft clears the clutch. Lower the transmission from the vehicle.

Installation

1. Place the transmission on a transmission lack such as Rotunda Transmission Jack 077-00008 or equivalent. Install guide studs in the engine block and raise the transmission until the input shaft splines are aligned with the clutch disc splines.
2. Slide the transmission forward on the guide studs until it is in position. lnstall the attaching bolts and tighten to 54-67 N.m (4O-50 ft-lb). Remove the guide studs and install the remaining bolts. Tighten the two bolts for the lower plate to 12-16 N.m (9-12 ft-lb).






3. Install the crossmember. Install bolts and tighten to 58-77 N.m (43-57 ft-lb). Install the nut retaining the insulator and retainer to crossmember. Tighten to 81-108 N.m (60-80 ft-lb). Remove the transmission jack.
4. Connect the speedometer cable and driven gear and clutch hydraulic line.
5. Connect the backup lamp switch.
6. Connect the driveshaft.
7. Install the shift lever retaining bolt and tighten to specifications. Specifications
8. Slide the shifter boot into position on the shifter shaft, and install the boot retaining screws.
9. Install the isolator pad assembly. Install the floor pan cover and floor mat.

Transmission (4x4)

Removal

1. Shift the transmission into neutral and remove the shift ball from the transfer case shift lever.
2. Remove the carpet or floor mat






A. Remove the seats
B. Grasp the carpet or mat surrounding edge beneath the convoluted floor shifter and pull it outward and upward away from the boot.
C. Remove the floor console.
D. Remove the screws retaining the RH and LH cowl side trim panels.
E. Remove all carpet or mat retaining screws.
3. Remove the shifter boot retainer screws and slide the boot up the shift lever shaft.
4. Remove the shift lever retaining bolt and remove the shift lever.
5. Raise the vehicle on a hoist.
6. Remove the drain plugs and drain the transmission and transfer case.
7. Remove the rear driveshaft from the transfer case.
8. Remove the front driveshaft from the transfer case.
9. Disconnect the backup lamp switch.
10. Remove the speedometer cable from the transfer case.
11. If equipped, remove the skid pad from beneath the transfer case.
12. Position a transmission jack such as Rotunda Transmission Jack 077-00008, under the transfer case. Remove the six bolts holding the transfer case to the transmission and carefully lower the transfer case from the vehicle, using care to ensure that the transfer case shift lever clears the opening in the floor pan.






13. Remove the transmission rear insulator and lower retainer.
Remove the crossmember.
A. Raise vehicle on a hoist.
B. Remove skid plate if equipped
C. Remove heat shield from catalytic converter.
14. Remove the bolts that retain the transmission to the engine block.
15. Move the transmission to the rear until the input shaft clears the clutch. Lower the transmission from the vehicle.

Installation

1. Place the transmission on a transmission jack such as Rotunda Transmission Jack 077-00008 or equivalent. and install two guide studs in the transmission front case top holes to guide, the transmission into position. Join together the transmission and engine block mating surfaces
2. Install the two lower bolts and tighten to 54-67 N.m (4O-5O ft-lbs).Remove the guide studs and install the upper bolts.






3. Place the rear support bracket in position and install the retaining bolts. Tighten the bolt to 60-80 N.M. (45-6O ft-lbs).
4. Install the two bolts at the rear support insulator bracket. Remove the transmission lack.






5. Position the transfer case on the transmission jack. Position the transfer case on the transmission using care to guide the transfer case shift lever through the opening in the floor pan. Install the gasket and six retaining bolts. Tighten the bolts to specifications. 34-58 N.m (25-43 ft-lb) in the sequence shown
6 Install the speedometer cable to the transfer case.
7. Connect the front drive shaft to the transfer case yoke or flange.
8. Connect the rear driveshaft to the transfer case yoke or flange.
9. Fill transfer case and transmission with Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or DDX E4AZ-19582-B (ESP-M2C166-H) or equivalent automatic transmission fluid
10. Connect the back-up lamp switch.
11. Lower vehicle.
12. Install the shift lever relaining bolt and tighten to specifications. Specifications
13. Slide the shifter boot into position on the shifter shaft and install the boot retaining screws.
14. Install the isolator pad assembly. Install the floor pan cover and floor mat.
15. Install the shift ball on the transfer case shift lever.