Installation

Transmission - Diesel Engines









Installation

NOTICE: Install a new auxiliary transmission fluid 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.

NOTICE: Prior to installation of a new or overhauled transmission, the transmission fluid cooler tubes must be cleaned.

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

Lubricate the torque converter pilot hub with multi-purpose grease.





2. Rotate the torque converter so the orange or green paint daub is in the 12 o'clock position.

3. If the Torque Converter Retainer has not been installed during the assembly of the transmission, install the Torque Converter Retainer to hold the torque converter in place while moving and positioning the transmission in place. Once the transmission is in place, prior to bolting it to the engine, remove the Torque Converter Retainer.





4. Install a new transmission filler tube O-ring.





5. Position the transmission in place. While raising the transmission up into the engine compartment, align the transmission filler tube with the stub tube on the transmission using the transmission 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. Position the bracket in place and install the 9 transmission-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).





7. Using the Strap Wrench, rotate the crankshaft to gain access to the torque converter studs.





8. Install the new torque converter-to-flexplate nuts.
- Tighten to 48 Nm (35 lb-ft).





9. Install the cylinder block opening cover.





10. Install the torque converter cover.
- Tighten to 35 Nm (26 lb-ft).





11. Position the transmission insulator and retainer and install transmission insulator and retainer bolts.
- Tighten to 94 Nm (69 lb-ft).





12. Install the transmission support crossmember.

13. Connect the transmission fluid cooler tubes onto the bracket.





14. Install the transmission fluid cooler tube inlet fitting.
- Tighten to 40 Nm (30 lb-ft).





15. Install the transmission fluid cooler tube outlet fitting.
- Tighten to 40 Nm (30 lb-ft).





16. Connect the wire harness to the bracket.





17. Install the wire harness on the LH side of the transmission.





18. Connect the wire harness on the RH side of the transmission.





19. Connect the Output Shaft Speed (OSS) sensor connector.





20. Connect the Turbine Shaft Speed (TSS) and intermediate shaft speed sensor connector.





21. Connect the transmission vehicle harness connector.
- Tighten to 5 Nm (44 lb-in).





22. Install the selector lever cable and selector lever cable bracket onto the transmission.

1. Position the selector lever cable bracket and install the selector lever cable bracket upper bolt and selector lever cable bracket lower stud bolt nut.
- Tighten to 48 Nm (35 lb-ft).

2. Connect the selector lever cable onto the manual control lever.

3. Connect the wire harness onto the selector lever cable bracket.





23. If equipped, install the selector lever cable onto the routing clip.





24. Install the rear driveshaft. For additional information, refer to Drive/Propeller Shafts, Bearings and Joints.

25. Use the following guidelines for the transmission fluid in-line filter:
- If the transmission was overhauled and the vehicle was equipped with a transmission fluid in-line filter, install a new transmission in-line filter.

- If the transmission was overhauled and the vehicle was not equipped with a transmission fluid in-line filter, install a new transmission in-line filter kit.

- If the transmission is being installed for a non-internal repair, do not install a transmission fluid in-line filter or filter kit.

- If installing a new or a Ford authorized remanufactured transmission, install a transmission fluid in-line filter.
Prior to lowering the vehicle, install a new transmission fluid in-line filter or a filter kit.

26. Adjust the selector lever cable. Verify that the vehicle starts in PARK and NEUTRAL and the reverse lamps illuminate in REVERSE. For additional information, refer to Automatic Transmission/Transaxle.

27. Install the transmission fluid level indicator.

28. 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 transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved (transmission fluid should be in the hot range cross-hatched area of the transmission fluid level indicator).