Installation

Special Tools:

Installation

Vehicles Not Equipped with 7.3L Engines

1. CAUTION: Prior to the installation of the transmission the fluid coolers, cooler lines and the cooler bypass valve will need to be cleaned.





Inspect the wiring harness and the connectors for damage, terminal condition, corrosion and seal integrity. Repair or replace as required.

2. CAUTION: Prior to installation of the transmission assembly, the torque converter pilot hub must be properly lubricated.





Lubricate the torque converter pilot hub.
- Use Ford Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-B.

3. If not installed during assembly, install the Torque Converter Holding Tool.

4. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS sensor may occur.

CAUTION: If a safety strap is being used to hold the transmission to the Highlift Transmission Jack, place the strap behind the Cooler Bypass Valve (CBV) to prevent damage to the cooler bypass valve.

Note: Prior to installation, inspect the transmission wiring harness and the connectors for damage, terminal condition, corrosion and seal integrity. Repair or replace as required.

Note: Due to the proximity of the exhaust pipe, the bolt must be installed into the converter housing mounting hole above the starter motor mounting area prior to raising the transmission into the vehicle.





Position, then raise the transmission into the vehicle while watching for obstructions.

5. CAUTION: Do not allow the torque converter drive flats to disengage from the pump gear. Use care not to damage the flexplate and the converter pilot. The torque converter must rest squarely against the flexplate, indicating the converter pilot is not binding in the crankshaft.





Align the (A) torque converter studs with the mounting holes in the (B) flexplate. Install the (C) transmission to the (D) engine.





6. Install and alternately snug the transmission-to-engine retaining bolts.





7. Install, snug, then tighten the new torque converter-to-flexplate nuts.





8. Install the cylinder block opening cover.





9. Install the flexplate inspection cover bolts.

10. Note: If the transmission fluid cooler, cooler tubes, or cooler bypass valve have not been flushed it would be necessary to do so at this time.





With a suitable drain pan properly positioned, remove the plugs and connect the fluid cooler tubes to the CBV.





11. Install the (A) exhaust heat shields, (B) bolts, and the cross over pipe.

12. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS sensor should occur.

Install the transmission support crossmember.





1 Install the (A) transmission support crossmember and the (B) nuts onto the (C) retainer and insulator.
2 Raise the transmission, aligning the (A) transmission support crossmember to the (D) frame.
3 Install the (E) stud brackets and the (F) nuts.





13. Remove the (A) Highlift Transmission Jack with the (B) E40D Transmission Jack Adapter from the (C) transmission.





14. Reinstall the transmission fluid pan-to-case retaining bolts removed to install the jack adapter.
15. Install the starter motor.
16. Install the driveshaft.





17. Install the shift cable.

18. Note: Also refer to the two illustrations.











Connect the electrical harness connectors at the (A) Vehicle Speed Sensor (VSS), the (B) digital Transmission Range (TR) sensor, the (C) solenoid body and the TSS, if equipped.
19. Remove the supports and lower the vehicle.





20. Install and alternately snug, then tighten the transmission-to-engine bolts.

21. Note: Prior to installation, check the condition of the transmission fluid filler tube O-ring. Replace if damaged.

Note: Also refer to the illustration.








Install the (A) fluid filler tube into the (B) short fluid inlet tube. Position the (C) retaining brackets and install the (E) nut and the (F) bolt.
22. Install the engine cover.

23. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicles battery has been disconnected for any type of service or repairs the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving operating conditions. There is no time frame set for this process. If a concern is present during down shifts or converter clutch apply, it is not the shift strategy and will require diagnosis.

The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this condition is temporary and will eventually return to normal operating condition.
- Connect the battery ground cable.

24. Install the air cleaner air intake duct assembly.
25. Fill the transmission to the specified Motorcraft MERCON V (R) Multi-Purpose (ATF) Transmission Fluid XT-5-QM or equivalent meeting MERCON V (R) specification.

Vehicles Equipped with 7.3L Engine

26. CAUTION: Prior to the installation of the transmission the fluid coolers, cooler lines and the cooler bypass valve will need to be cleaned.

Inspect the wiring harness and the connectors for damage, terminal condition, corrosion and seal integrity. Repair or replace as required.

27. CAUTION: Prior to installation of the transmission assembly, the torque converter pilot hub must be properly lubricated.





Lubricate the torque converter pilot hub.
- Use Ford Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-B.

28. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS sensor may occur.

CAUTION: If a safety strap is being used to hold the transmission to the Highlift Transmission Jack, place the strap behind the Cooler Bypass Valve (CBV) to prevent damage to the cooler bypass valve.

Note: Prior to installation, inspect the transmission wiring harness and the connectors for damage, terminal condition, corrosion and seal integrity. Repair or replace as required.

Note: Due to the proximity of the exhaust pipe, the bolt must be installed into the converter housing mounting hole above the starter motor mounting area prior to raising the transmission into the vehicle.





Position, then raise the transmission into the vehicle while watching for obstructions.

29. CAUTION: Do not allow the torque converter drive flats to disengage from the pump gear. Use care not to damage the flexplate and the converter pilot. The torque converter must rest squarely against the flexplate, indicating the converter pilot is not binding in the crankshaft).





Align the (A) torque converter studs with the mounting holes in the (B) flexplate. Install the (C) transmission to the (D) engine.

30. Note: Also refer to the following illustration.








Install and alternately snug the 2 transmission-to-engine retaining bolts.





31. Install, snug, then tighten the new torque converter-to-flexplate nuts.
32. Alternately tighten the transmission-to-engine bolts.





33. Install the (A) flexplate inspection cover and the 5 (B) bolts.

34. Note: If the transmission fluid cooler, cooler tubes, or cooler bypass valve have not been flushed it would be necessary to do so at this time.





With a suitable drain pan properly positioned, remove the plugs and connect the fluid cooler tubes to the CBV.

35. Note: Also refer to the two following illustrations.











Connect the electrical harness connectors at the (A) Vehicle Speed Sensor (VSS), the (B) digital Transmission Range (TR) sensor, the (C) solenoid body and the TSS, if equipped.





36. Install the (A) heat shield. Tighten the (B) bolts.

37. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS sensor should occur.





Install the transmission support crossmember.
1 Install the (A) transmission support crossmember and the (B) nuts onto the (C) retainer and insulator.
2 Raise the transmission, aligning the (A) transmission support crossmember to the (D) frame.
3 Install the (E) stud brackets and the (F) nuts.





38. Remove the (A) Highlift Transmission Jack with the (B) E40D Transmission Jack Adapter from the (C) transmission.





39. Reinstall the transmission fluid pan-to-case retaining bolts removed to install the jack adapter.
40. Install the starter motor.
41. Install the driveshaft.





42. Install the shift cable.
43. Remove the supports and lower the vehicle.





44. Install and alternately snug, then tighten the transmission-to-engine bolts.

45. Note: Prior to installation, check the condition of the transmission fluid filler tube O-ring. Replace if damaged.

Note: Also refer to the following illustration.








Install the (A) fluid filler tube into the (B) short fluid inlet tube. Position the (C) retaining brackets and install the (E) nut and the (F) bolt.
46. Install the engine cover.

47. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicles battery has been disconnected for any type of service or repairs the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving operating conditions. There is no time frame set for this process. If a concern is present during down shifts or converter clutch apply, it is not the shift strategy and will require diagnosis.

The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this condition is temporary and will eventually return to normal operating condition.
Connect the battery ground cable.

48. Install the air cleaner air intake duct assembly.
49. Fill the transmission to the specified Motorcraft MERCON V (R) Multi-Purpose (ATF) Transmission Fluid XT-5-QM or equivalent meeting Ford MERCON V (R) specification.