Installation

Transmission - Excursion





Special Tool(s)





Material

Installation

All applications

CAUTION: Install a new oil-to-air (OTA) cooler as part of a transmission overhaul, or when installing a remanufactured transmission due to major metallic failure, multiple clutches or clutch plate failures or sufficient component wear, which results in metallic contamination.

1. CAUTION: Prior to the installation of the transmission, the fluid cooler lines must be cleaned. Otherwise transmission failure can occur.

Clean the fluid cooler lines.

2. CAUTION: Prior to the installation of the transmission, a new transmission fluid cooler remote filter must be installed. Otherwise transmission failure can occur.

Install a new transmission fluid cooler remote filter.





3. CAUTION: Prior to the installation of the assembly, the torque converter pilot hub must be correctly lubricated or damage to the torque converter or the engine crankshaft can occur.

Lubricate the torque converter pilot hub with multipurpose grease.





4. If the special tool has not been installed during the assembly of the transmission, install the special tool to hold the torque converter in place while moving and positioning the transmission in place. Once the transmission is in place and before bolting it to the engine remove the special tool.





5. Position the transmission in place. While raising the transmission into the engine compartment, align the fluid filler tube with the stub tube on the transmission using the fluid level indicator as a guide.
^ While installing the transmission to the engine, align the torque converter studs with the mounting holes in the flexplate.





6. Install nine transmission-to-engine bolts.





7. NOTE: Using a suitable strap wrench, rotate the crankshaft pulley to gain access to the torque converter nuts.

Install six new torque converter-to-flexplate nuts.





8. Install the cylinder block opening cover.





9. Install the front transmission fluid cooler tube.





10. Install the rear transmission fluid cooler tube.

4x4 applications
11. Support the extension housing with a Jack stand and remove the transmission Jack.

4x2 applications





12. Install the transmission mount.





13. Position the crossmember to the transmission mount and loosely install the nut.





14. Install the LH crossmember bolts.





15. Install the RH crossmember bolts.





16. Tighten the rear insulator nuts.





17. NOTE: RH shown.

Connect the RH and LH wiring harness to the side of the transmission.





18. Connect the Output Shaft Speed (OSS) sensor electrical connector.





19. Connect the intermediate shaft and turbine shaft combination speed sensor electrical connector.





20. Connect the solenoid body electrical connector.





21. Connect the shift cable.
1 Install the cable housing bracket.
2 Install the shift cable to the manual lever.

4x2 applications





22. Reconnect the wire harness to the frame.

4x4 applications
23. If equipped, install the transfer case.

4x2 applications
24. Install the rear driveshaft.

All applications
25. Connect the battery ground cable.
26. Adjust the shift linkage. Verify that the vehicle starts in PARK and NEUTRAL and the REVERSE lamps illuminate in REVERSE.
27. With the engine running and the transmission at normal operating temperature 66 - 77°C (150 - 170°F), check and adjust the transmission fluid level, and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).
28. Use the following guidelines for 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 non-internal repair, do not install an in-line filter or filter kit.
^ If installing a new or a Ford-authorized remanufactured transmission, install a in-line transmission fluid filter.
Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit.