Installation
Transmission Installation
Material
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.
3. Remove the special tool.
4.0L SOHC engine
4. 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-in) screws.
2. Install 4 M10 x 50-mm (2-in) screws.
3. Install 2 M10 x 75-mm (3-in) screws.
2.3L and 3.0L engines
5. 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.
6. 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
7. Install the lower transmission-to-engine screws.
8. Install the HO2S connector bracket.
9. Install the rear engine cover plate.
4x4 vehicles
10. Install the transfer case.
All vehicles
11. Install the screws.
1. Install the exhaust bracket.
2. Install the screws.
4x2 vehicles
12. Install the crossmember.
^ Position the crossmember.
^ Install the six bolts (three each side).
4x4 vehicles
13. Install the crossmember.
1. Position the crossmember.
2. Install the six crossmember bolts (three each side).
All vehicles
14. Install the transmission mount into the crossmember and tighten the nuts.
3.0L engines
15. If equipped, install the rear vibration damper.
3.0L and 4.0L SOHC engines
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-ring seals. If damaged, new O-ring seals must be installed.
Hold the case fitting and install the transmission cooler lines.
17. Install four new torque converter nuts.
^ Rotate the crankshaft as needed to gain access to all the nuts.
2.3L vehicles
18. CAUTION: When installing the torque converter nuts, the crankshaft must be rotated only in the clockwise direction, otherwise engine damage can occur. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction between the flange faces on each part. For that reason, the crankshaft sprocket can also be moved when the crankshaft pulley is turned in the counterclockwise direction.
Install four new torque converter 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. Position the transmission wiring harness in place.
1. Clip harness to the shift cable bracket.
2. Clip harness retainer to the case.
22. 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.
23. Install the shift cable.
1. Connect the shift cable to manual control lever.
2. Connect the shift cable to the bracket.
24. NOTE: Align the driveshaft yoke and the axle shaft marks made at removal to maintain driveline balance.
Align and install the rear driveshaft.
25. Install the driveshaft bolts.
26. 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 new or a Ford-authorized remanufactured 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.
4.0L SOHC Vehicles
27. Install the transmission fill tube and indicator as an assembly.
All Vehicles
28. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer must 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.
29. Fill the transmission with clean automatic transmission fluid to the specified level.
30. Check the transmission for correct operation.
31. Verify that the shift cable is correctly adjusted.