Installation
NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid.
Installation
1. Tighten converter housing access plug to 28-30 Nm (21-22 lb-ft).
2. Position the torque converter on the transmission, ensuring the converter drive flats are fully engaged in the pump gear by rotating the torque converter.
3. CAUTION: Lubricate torque converter pilot with Multi-Purpose Grease D0AZ-19584-AA or equivalent.
Place the transmission on the transmission jack. Secure the transmission to the jack with a chain.
4. Rotate the torque converter until the studs and converter housing access plug are in alignment with the holes in the flywheel.
5. Align the orange balancing marks on converter stud and flywheel bolt hole if balancing marks are present.
6. NOTE: Before installing the torque converter to the flywheel retaining nut, a check should be made to ensure that the torque converter is properly seated. The torque converter should move freely with respect to the flywheel. Grasp the stud. Movement back and forth should result in a metallic clank noise if the converter is properly seated. If the torque converter will not move, the transmission must be removed and the torque converter repositioned so that the impeller hub is properly engaged in the pump gear.
Move the torque converter and transmission assembly forward into position, using care not to damage the flywheel and the converter pilot. The torque converter face must rest squarely against the flywheel. This indicates that the converter pilot is not binding in the engine crankshaft.
7. Connect exhaust gas recirculation (EGR) tube to torque converter assembly.
8. Position converter housing to cylinder block and attach with five converter housing bolts. Position the transmission fluid filler tube on the converter housing and attach with converter housing bolt. Tighten six bolts to 50-68 Nm (37-50 lb-ft).
9. NOTE: Place a wrench on the crankshaft pulley bolt to turn the converter to gain access to the nuts.
Install the four converter nuts through the starter motor hole.
10. Install starter motor and secure with two bolts. Tighten bolts to 20-27 Nm (15-20 lb-ft).
11. Connect cable to the terminal on starter motor with nut. Tighten to 5-10 Nm (45-89 lb-in).
12. Position transmission shift cable and bracket to the transmission and secure with nut and bolt.
13. Position the extension housing insulator on the extension housing and attach with two bolts. Tighten to 88-119 Nm (65-87 lb-ft).
14. Position the transmission support crossmember on the side supports and attach with two through bolts and nuts. Tighten to 87-110 Nm (64-81 lb-ft).
15. Use four bolts and nuts to attach the transmission support crossmember to side supports. Tighten to 87-110 Nm (64-81 lb-ft).
16. Attach the extension housing insulator to the transmission support crossmember to the side supports. Tighten to 98-132 Nm (73-97 lb-ft).
17. Remove the chain from the transmission and remove the transmission jack from under the vehicle.
18. Position driveshaft yoke inside extension housing.
19. Position driveshaft on the rear axle and secure with four bolts. Tighten to 88-119 Nm (65-87 lb-ft).
20. Position RH exhaust inlet pipe on vehicle. Attach exhaust inlet pipe to exhaust manifold with two bolts and tighten to 34-46 Nm (25-34 lb-ft).
21. Position LH exhaust inlet pipe on vehicle. Attach exhaust inlet pipe to exhaust manifold with two bolts and tighten to 34-46 Nm (25-34 lb-ft).
22. Position LH and RH exhaust inlet pipes on dual three-way catalytic converter and attach with four nuts and bolts. Tighten to 34-46 Nm (25-34 lb-ft).
23. Connect two transmission cooler lines to transmission. Tighten to 20-26 Nm (15-19 lb-ft).
24. Connect the 16-pin transmission electrical connector and attach with screw.
25. Connect the transmission range (TR) sensor electrical connector.
26. Remove the four heated oxygen sensors (HO2S). Refer to Section 03-14.
27. Lower vehicle.
28. Connect battery.
29. Fill transmission with MERCON or MERCON V Automatic Transmission Fluid or equivalent FORD approved fluid.
30. Start engine and check transmission operation.