Installation

1. Make sure that the machined mating surfaces and the locating dowels on the engine are free of burrs, dirt or paint. Check the mating face of the transmission and the locating dowel holes for burrs, dirt or paint.
2. Mount the transmission on a transmission jack such as Hi-Lift Transmission Jack 014-00942 or equivalent. Position it under the vehicle and start the input shaft into the clutch disc. Align the splines on the input shaft with the splines in the clutch disc. Move the transmission forward and carefully seat the case on the locating dowels of the engine. The dowels must not shave or burr the dowel holes.
3. install the bolts and flatwashers that attach the transmission to the engine and tighten to 38-51 Nm (28-38 ft. lbs.).
4. Install the starter motor. Tighten the attaching bolts to specifications.
5. Raise the engine and install the rear crossmember, transmission support insulator, and attaching nuts and washers. Tighten nuts to 65-85 Nm (48-63 ft. lbs.). Remove the transmission jack.
6. Install the transfer case.
7. On SuperCab vehicles, insert the driveshaft into the extension housing and install the center bearing attaching nuts, washers and lockwashers. Tighten the nuts to specification.
8. Connect the driveshaft to the rear axle drive flange. Tighten the attaching nuts to specifications.
9. Connect wires for the starter motor and backup lamp switch.
10. Reinstall exhaust system.
11. Connect the hydraulic clutch hose and bleed the system.
12. Install the speedometer cable.
13. Check fluid level. Fill transmission with Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or -DDX or equivalent MERCON fluid.
14. Remove safety stands and lower the vehicle.
15. Connect the battery ground cable to the battery terminal.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.