Installation

Special Tools:

Special Service Tool(s)
Installation
All Applications

1. CAUTION: Prior to the installation of the transmission, the fluid, cooler lines and the cooler bypass valve will need to be cleaned. Transmission failure could occur if not cleaned.

CAUTION: The transmission Oil-To-Air Cooler (OTA) will need to be replaced if the transmission was overhauled or exchanged due to a failure of the transmission. Transmission failure could occur.

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





2. CAUTION: Prior to the installation of the transmission assembly, the torque converter pilot hub must be properly lubricated or damage to the torque converter or the engine crankshaft could occur.

Lubricate the torque converter pilot hub.
- Use Ford Multipurpose Grease D0AZ-19584-AA or equivalent meeting Ford specification ESB-MlC93-B.
3. If not installed during assembly, install the Torque Converter Holding Tool.





4. CAUTION: Do not use the cooler bypass valve as a handle. Damage to the cooler bypass valve assembly may occur or damage to the case may result.

CAUTION: Be careful not to raise the transmission up too far. The sensors may make contact with the underbody of the vehicle and cause damage to the sensors. Sensor failure or leakage may occur.

Position the transmission
- Raise the rear of the transmission to clear the crossmember.
5. Remove the Torque Converter Holding Tool





6. 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 engine.

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





7. Install seven transmission-to-engine bolts.
8. Install the exhaust and crossmember.





9. Remove the High-Lift Transmission jack.





10. Install the new torque converter-to-flexplate nuts.
- Rotate flexplate to gain access to the nuts.





11. Install the flexplate inspection cover bolts.





12. Install the cylinder block opening cover.
13. Install the starter.

4x4 Applications
14. Install the transfer case assembly.

4x2 Applications





15. Note: To maintain initial driveshaft balance, align the index marks made during removal.

Install the rear driveshaft.
1 Position the driveshaft.
2 Install the four bolts.

All Applications





16. Connect the solenoid pack electrical connector.





17. Connect the Digital Transmission (TR) sensor connector.





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





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

Install the transmission fluid cooler tubes to the cooler bypass valve.





20. Install the transmission fluid filler tube into the transmission stub tube.





21. Install the transmission fluid filler tube bolt.

23. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair 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 Manual (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If a concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis as outlined in the workshop manual.
The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition.

Connect the battery ground cable.
24. Fill to proper level with Motorcraft MERCON V Multipurpose (ATF) Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON V.