Installation
INSTALLATIONTransmission
4x4 vehicles
1. Install the vent tube assembly.
All vehicles
2. WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions may result in personal injury.
Raise and position the transmission.
4.0L SOHC engine
3. NOTE: Align the flexplate to the converter marks made at removal.
Install the transmission-to-engine screws.
1 Install 2 M10 x 40 mm (1.6 inch) screws.
2 Install 4 M10 x 50 mm (2 inch) screws.
3 Install 2 M10 x 75 mm (3 inch) screws.
2.3L and 3.0L engines
4. NOTE: Align the flexplate to the converter marks made at removal.
Install the screws.
1 Install 1 M10 x 40 mm (1.6 inch) screw.
2 Install 4 M10 x 50 mm (2 inch) screws.
3 Install 2 M10 x 75 mm (3 inch) screws.
5. Install the upper fluid filler tube and bracket screw.
1 Install the upper filler tube.
2 Install the M10 x 40 mm (1.6 inch) bracket screw.
2.3L engine
6. Install the lower transmission-to-engine screws.
7. Install the H02S connector bracket.
8. Install the rear engine cover plate.
4x4 vehicles
9. Install the transfer case.
All vehicles
10. Install the screws.
1 Install the exhaust bracket.
2 Install the screws.
4x2 vehicles
11. Install the crossmember.
1 Position the crossmember.
2 Install the eight bolts (four each side).
4x4 vehicles
12. Install the crossmember.
1 Position the crossmember.
2 Install the six crossmember bolts (three each side).
All vehicles
13. Install the transmission mount into the crossmember and tighten the nuts.
3.0 L engines
14. Install the rear vibration damper.
All vehicles
15. Remove the High-Lift Transmission Jack.
16. CAUTION: Care should be taken not to bend or damage the cooler lines.
NOTE: Prior to installing the cooler lines to the case, inspect the O-rings. If damaged new O-rings will need to be installed.
Hold the case fitting and install the transmission cooler lines.
17. Install the four nuts.
^ Rotate the crankshaft as needed to gain access to all the nuts.
2.3L vehicles
18. Install the four nuts.
^ Rotate the crankshaft as needed to gain access to all the nuts.
All vehicles
19. Install the starter motor.
20. Install the catalytic converter assembly.
21. Connect the transmission wiring harness.
1 Connect the transmission connector.
2 Connect the Intermediate Shaft Speed (ISS) sensor.
3 Connect the digital Transmission Range (TR) sensor connector.
4 Connect the Output Shaft Speed (OSS) sensor.
22. Install the shift cable.
1 Connect the shift cable to manual control lever.
2 Connect the shift cable to the bracket.
23. NOTE: Align the driveshaft yoke and the axle shaft marks made at removal to maintain driveline balance.
Install the rear driveshaft.
1 Position the driveshaft.
2 Install the four bolts.
24. Use the following guidelines for installing the in-line transmission fluid filter:
^ If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a new in-line fluid filter.
^ If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter, install a new in-line fluid filter kit.
^ If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter kit.
^ If installing a Ford-authorized re-manufactured transmission, install the in-line transmission fluid filter that is supplied.
^ Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit.
25. Lower the vehicle.
4.0 L SOHC vehicles
26. Install the transmission fill tube and indicator as an assembly.
All vehicles
27. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience ,slightly different upshifts (either soft or firm) and that this is a temporary condition. The vehicle will eventually return to normal operating condition.
Connect the battery ground cable.
28. Fill the transmission with clean automatic transmission fluid and inspect for correct operation.
29. Verify that the shift cable is correctly adjusted.