Installation
NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid.
Installation
1. Position the torque converter to the transmission. Align the converter to the front pump by rotating the converter and pushing it inward until full engagement is made. Lightly lubricate the converter pilot hub using Ford Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-B.
2. NOTE: The torque converter must rest squarely against the flexplate. This indicates that the converter pilot is not binding in the crankshaft.
Position the transmission under the vehicle. Raise the transmission into position. Do not allow the torque converter drive flats to disengage the pump gear. Rotate the converter to align the studs with the flexplate mounting holes. Position the transmission to the engine.
3. NOTE: The top right transmission-to-engine bolt, retaining the fluid level indicator tube and harness bracket, must be installed after the other transmission-to-engine bolts have been installed and tightened.
Install the connector bracket, fluid level indicator tube, and six transmission-to-engine bolts. Tighten the bolts to 44-60 Nm (32-44 lb-ft). Connect the 16-pin harness connectors.
4. Remove the engine support.
5. CAUTION: Use care not to bend or otherwise damage the cooler lines. 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. Install the transmission cooler lines. Tighten the fittings to 35-43 Nm (26-32 lb-ft). Securely install the bolt retaining the cooler line bracket to the engine block.
6. Install new torque converter nuts. Tighten the nuts to 34-46 Nm (25-34 lb-ft).
7. Install the torque converter access cover. Securely install two access cover bolts.
8. Raise the transmission and position the Y-pipe to the exhaust manifolds. Loosely install the hanger bracket bolt. Install the converter-to-tailpipe flange bolts and the Y-pipe-to-manifold bolts. Tighten the bolts to 34-46 Nm (25-34 lb-ft).
9. Install the exhaust hanger at the transmission support insulator. Tighten the retainer to 20-27 Nm (15-20 lb-ft).
10. Position the crossmember. Install the bolts and nuts. Tighten the retainers to 37-52 Nm (27-38 lb-ft).
11. Lower the transmission guiding support insulator studs into the crossmember. Install the transmission support insulator nuts. Tighten the nuts to 85-118 Nm (63-87 lb-ft).
12. Lower and remove the transmission jack from under the vehicle.
13. Connect the HO2S connectors and install the shift cable to the shift cable bracket. Connect the shift cable to the manual control lever.
14. Install the oil filter funnel and the starter motor. Install the bolts and tighten them to 22-28 Nm (16-21 lb-ft). Securely install the oil filter funnel bolt and nut.
15. Lightly coat the slip yoke with Premium Long-life Grease XG-1-C (or -K, or equivalent meeting Ford specification ESA-M1C75-B).
16. Remove the extension housing plug and install the driveshaft. Rotate the driveshaft and align it to the index mark made during removal. Install the bolts and tighten them to 83-118 Nm (61-87 lb-ft). Install two midship bearing clips and bolts. Tighten the retainers to 37-50 Nm (27-37 lb-ft).
17. Remove the jack stands.
18. Lower the vehicle.
19. From inside the vehicle, place the gearshift lever in the DRIVE or OVERDRIVE position. Hang a weight of 1.4 kg (3 lb) on the gearshift lever to verify the lever is located firmly on the D or OVERDRIVE detent.
20. Raise the vehicle.
21. Remove the shift cable from the transmission lever ball stud. Pull down on the lock tab on the shift cable body. Position the gearshift lever in the DRIVE position. (This is three detents from the frontmost 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 and lock the cable in the correctly adjusted position.
22. Lower the vehicle.
23. Install the fan shroud-to-radiator bolts. Tighten the bolts to 6-8 Nm (53-71 lb-in).
24. Connect the negative battery cable.
25. Fill the transmission to the proper level with Motorcraft Mercon or MERCON V Automatic Transmission Fluid or equivalent meeting FORD specification and install the fluid level indicator.
26. Check the operation of the transmission.
27. Remove the three-pound 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.