Installation
NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid.
Install
1. Position the torque converter to the transmission. Align the converter to the front pump by rotating and pushing it inward until full engagement is made. Lightly lubricate the torque converter pilot hub using Ford Mutli-Purpose Grease DOAZ-19584-AA (or equivalent.)
2. CAUTION: The torque converter drive flats must not disengage from the pump gear.
NOTE: The torque converter must rest squarely against the flexplate. This indicates that the torque converter pilot is not binding in the engine crankshaft.
Position the transmission and jack under the vehicle. Raise the transmission into position. Rotate the torque converter to align the indexed stud with the index mark and with flexplate mounting holes. Position the transmission to the engine.
3. Install seven transmission-to-engine bolts. Tighten the bolts to 38-51 Nm (28-38 lb-ft).
4. Connect both transmission 16-pin connectors at the left and right rear cylinder heads. Position and connect the transfer case vent hose and shift motor connector. Install the vehicle speed (VSS) sensor. Install and securely tighten the vehicle speed (VSS) sensor retaining nut. Connect the vehicle speed (VSS) sensor connector.
5. Position the transmission crossmember and loosely install the mount nuts. Install the left and right crossmember bolts and nuts. Tighten the nuts to 85-118Nm(63-87 lb-ft). Lower the transmission. Tighten the mount nuts to 85-118Nm (63-87 lb-ft).
6. Remove the engine support jack stand.
7. NOTE: Use the crankshaft pulley bolt to rotate the converter.
Install four new torque converter nuts. Tighten the nuts to 27-46Nm(20-34 lb-ft).
8. Disconnect and remove the safety strap from the transmission. Lower and remove the transmission jack from under the vehicle.
9. Position the transmission fill tube and install the bolt. Tighten the bolt to 38-51Nm (28-38 lb-ft).
10. CAUTION: Use care not to bend or damage the cooler lines. The case connector fittings must be held in place to prevent them from moving while tightening the tube nut.
Remove the caps from the transmission cooler lines and fittings. Install the lines. Tighten the fittings to 35-43Nm (26-32 lb-ft).
11. Position the starter motor. Install the stud and bolt. Tighten the retainers to 22-28Nm (16-21 lb-ft). Position the ground wire at the starter motor stud and securely install the nut.
12. Connect the shift cable to the bracket and lever.
13. Position the crossover pipe to the exhaust manifolds and loosely install the bolts.
14. Using new gaskets, position the converter assembly between the muffler inlet and crossover pipe outlet. Install the retainers at the muffler inlet and crossover pipe outlet. Tighten the retainers to 34-46Nm (25-34 lb-ft). Connect three HO2S connectors and locators. Tighten the crossover pipe-to-exhaust manifold bolts to 34-46Nm (25-34 lb-ft).
15. Position the front driveshaft and install the bolts. Tighten the bolts at the front axle flange to 15-20Nm (11-15 lb-ft). Tighten the transfer case flange bolts to 21-32 Nm (16-24 lb-ft.)
16. Position the rear driveshaft and install the bolts. Tighten the bolts to 88-118Nm (65-87 lb-ft).
17. Position the skid plate and install the bolts. Tighten the bolts to 22-28Nm (16-21 lb-ft).
18. Lower the vehicle.
19. Install the fan shroud-to-radiator bolts. Tighten the bolts to 6-8Nm (53-71 lb-in).
20. Place the shift control selector lever in the D or OVERDRIVE position. Hang a 1.4 kg (3 lb) weight on the end of the shift control selector lever.
21. Raise the vehicle.
22. Pry the shift cable end from the manual control lever ball stud. Release the lock tab on the top side of the cable by pushing down on two tangs. Move the shift cable back and forth through the full adjustment length four or five times, in order to remove any dirt. Make sure the adjuster body moves freely. Shift the transmission to the D position by moving the transmission lever all the way forward (clockwise) and then rearward three detent positions. Holding the cable end fitting, push the cable rearward until the end fitting lines up with the outer manual control lever ball stud. Connect the cable end fitting to the ball stud. Push up on the lock tab to lock the adjuster body in the correctly adjusted position. Make sure the locator tab is properly seated in the bracket. Make sure the shift cable is clipped to the floor pan at the white cable mark and that the cable is routed into the tunnel.
23. Lower the vehicle.
24. Connect the negative battery cable.
25. Fill the transmission to the proper level with Motorcraft MERCON or MERCON V Automatic Transmission Fluid or meeting FORD specification and install the fluid level indicator.
26. Remove the 1.4 kg (3 lb) weight from the shift control selector lever. After the adjustment, check for P position engagement. Check the shift control selector lever in all positions with the engine running to make sure the transmission/detent action is correct. Readjust as necessary.
27. Check the operation of the transmission.