Installation

NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid.


Install


1. Install transmission and tighten bolts to 44-60 N-m (32-44 lb-ft).

2. CAUTION: Use care not to bend or otherwise damage the cooler lines.

NOTE: The case connector fitting must be held in place to prevent it from moving while tightening the tube nut.


Remove the caps from the lines and fittings. Securely install the transmission cooler lines to the transmission fittings.

3. Install new torque converter nuts and tighten them to 34-46 Nm (25-34 lb-ft).

4. Position the dual TWC converter assembly to the exhaust manifolds. Install four bolts and tighten them to 34-46 Nm (25-34 lb-ft).

5. Install the exhaust hanger to the transmission mount. Tighten the retainer to 20-27 Nm (15-20 lb-ft).

6. Raise the transmission, position the crossmember, and install through bolts and nuts. Tighten the retainers to 37-52 Nm (27-38 lb-ft).

7. Lower the transmission onto the crossmember. Remove the transmission jack adapter plate from the transmission. Lower and remove the jack.

8. Install the nuts to the transmission support insulator. Tighten the nuts to 85-118 Nm (63-87 lb-ft).

9. Reconnect the 8-pin and 16-pin connectors at the left rear cylinder head, reconnect the HO2S, and install the shift indicator cable to the bracket and lever.

10. Position the transmission access cover and install the two transmission access cover screws. Tighten them to 16-22 Nm (12-16 lb-ft).

11. Position the starter motor and ground wire. Install the bolts and tighten them to 22-28 Nm (16-21 lb-ft).

12. Lightly coat the slip yoke with High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent.

13. Remove the plug and install the driveshaft. Rotate the driveshaft and align it with the index mark made during removal. Install the bolts and tighten them to 83-118 Nm (61-87 lb-ft).

14. Remove the safety stands.

15. Lower the vehicle.

16. Connect the negative battery cable.

17. Fill the transmission to the proper level with Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent and install the indicator.

18. NOTE: A weight of 1.4kg (3 lb) must be hung on the gearshift lever to verify the lever is located firmly on the DRIVE or the OVERDRIVE detent.


From inside the vehicle, place the gearshift lever in the DRIVE or the OVERDRIVE position.

19. Raise the vehicle.

20. Remove the shift cable from the transmission lever ball stud. Pull the lock tab down on the shift cable body. Position the gearshift lever in the DRIVE position (three detents from the front-most lever position, with the first position counted as one). Connect the cable end fitting to the transmission lever ball stud. Push up on the lock tab to lock the cable in the correctly adjusted position.

21. Lower the vehicle.

22. Remove the 1.4kg (3 lb) weight from the gearshift lever. After making the adjustment, check for park engagement. Check the gearshift lever in all detent positions with the engine running to verify correct detent/transmission actions. Readjust if necessary.