Section 665 (Automatic Transmission - 4R100 - Excursion & F250-F550 Super Duty): Assembly: Transmission

Special Tool(s) 

Fig 1: Identifying Transmission Special Tool(s) (1 Of 2)

Courtesy of FORD MOTOR CO.

Fig 2: Identifying Transmission Special Tool(s) (2 Of 2)

Courtesy of FORD MOTOR CO.

Material 

All applications 

1. Mount the transmission case into suitable stand.
2. If removed, use the special tool to install the short fluid inlet tube.
   Fig 3: Installing Short Fluid Inlet Tube

   Courtesy of FORD MOTOR CO.
CAUTION: If equipped, use care not to misalign the reverse clutch piston in the case bore.
NOTE: Coat the reverse clutch piston seals with petroleum jelly.
Fig 4: Installing Reverse Clutch Piston In Case Until It Fully Seated In The Case
Courtesy of FORD MOTOR CO.
3. Install the reverse clutch piston in the case until it is fully seated in the case.
CAUTION: The low/reverse clutch inner race is vehicle-dependent.
NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.
4. Install the reverse clutch return spring assembly.
   1. Install the reverse clutch return spring assembly.
   2. Install the low/reverse one-way clutch inner race.
   3. Make sure that the lubrication hole on the face is in the 5 o'clock position.
      Fig 5: Installing Low/Reverse One-Way Clutch Inner Race

      Courtesy of FORD MOTOR CO.
5. Install two 5/16-24 x 3 inch bolts with nuts into the low/reverse one-way clutch inner race.
   1. Hold the nut.
   2. Turn the bolt to compress the low/reverse piston return spring.
      Fig 6: Installing Nuts Into Low/Reverse One-Way Clutch Inner Race

      Courtesy of FORD MOTOR CO.
6. Install three of the one-way clutch inner race bolts and remove the two 5/16-24 x 3 bolts.
   Fig 7: Installing Three Of One-Way Clutch Inner Race Bolts

   Courtesy of FORD MOTOR CO.
NOTE: Alternate tightening bolts from one side to the other (not in a circle).
Fig 8: Installing Remaining Bolts Retaining Low/Reverse One-Way Clutch Inner Race-Case
Courtesy of FORD MOTOR CO.
7. Install the remaining bolts retaining the low/reverse one-way clutch inner race to the case.
CAUTION: The low/reverse clutch, one-way clutch is vehicle-dependent.
NOTE: When the reverse clutch and the low one-way clutch are installed, the reverse clutch should rotate clockwise. The one-way clutch will hold and not let the clutch hub rotate counterclockwise.
Fig 9: Installing Reverse Clutch Hub And Low One-Way Clutch Assembly
Courtesy of FORD MOTOR CO.
8. Install the reverse clutch hub and the low one-way clutch assembly over the low/reverse one-way clutch inner race by pressing the hub inward and rotating it clockwise to seat fully.
CAUTION: The number of plates is vehicle-dependent.
NOTE: No stack-up clearance measurement is required.
NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.
9. Install the reverse clutch pack assembly.
   1. Install the cushion spring.
   2. Install the reverse clutch plates starting with an external spline steel plate and alternating with internal splined friction plates
   3. Install the reverse clutch pressure plate
   4. Install the reverse clutch pressure plate retainer snap ring with the ring opening between the 12 o'clock and 3 o'clock positions.
      Fig 10: Installing Cushion Spring

      Courtesy of FORD MOTOR CO.
NOTE: Apply petroleum jelly to the No. 13 parking gear bearing to hold it in place.
Fig 11: Installing Parking Gear Bearing
Courtesy of FORD MOTOR CO.
10. Install the No. 13 parking gear bearing.
CAUTION: Use care not to damage the output shaft drive sprocket speed sensor wheel. This will cause an incorrect reading at the output shaft speed (OSS) sensor, which will cause a repeat repair.
Fig 12: Installing Output Shaft
Courtesy of FORD MOTOR CO.
11. Install the output shaft.
NOTE: Lubricate the thrust bearing with petroleum jelly to hold it in place during assembly.
Fig 13: Installing Thrust Bearing Onto Rear Surface Of Hub Assembly
Courtesy of FORD MOTOR CO.
12. Install the No. 12 thrust bearing onto the rear surface of the hub assembly.
13. Install the output shaft ring gear assembly.
    Fig 14: Installing Output Shaft Ring Gear Assembly

    Courtesy of FORD MOTOR CO.
WARNING: Do not overextend the output shaft retaining ring during installation. Make sure the output shaft retaining ring is securely seated in the groove. Failure to follow these instructions may result in personal injury.
Fig 15: Installing New Output Shaft Retaining Ring Onto Output Shaft
Courtesy of FORD MOTOR CO.
14. Install the new output shaft retaining ring onto the output shaft.
15. Install the reverse planet assembly.
    1. Install the No. 11 thrust washer.
    2. Install the reverse planet.
    3. Install the No. 10B thrust washer.
       Fig 16: Installing Reverse Planet Assembly

       Courtesy of FORD MOTOR CO.
16. Install the reverse planet retaining ring into the reverse clutch hub, making sure the retaining ring is fully seated.
    Fig 17: Installing Reverse Planet Retaining Ring

    Courtesy of FORD MOTOR CO.
NOTE: The large outer diameter radius of the needle bearing must be installed facing inward.
NOTE: Lightly lubricate the needle bearing with petroleum jelly to hold it in place during assembly.
Fig 18: Installing Forward Clutch Needle Bearing
Courtesy of FORD MOTOR CO.
17. Verify the No. 8B forward clutch needle bearing is installed.
18. Install the forward clutch cylinder assembly onto the intermediate brake drum by rotating it until fully seated.
    Fig 19: Installing Forward Clutch Cylinder Assembly

    Courtesy of FORD MOTOR CO.
NOTE: Lightly lubricate the thrust bearing with petroleum jelly to hold it in place during assembly.
Fig 20: Installing (Black Side Facing Up)
Courtesy of FORD MOTOR CO.
19. Verify the No. 9A forward clutch thrust bearing is installed (black side facing up).
NOTE: Lightly lubricate the thrust washer with petroleum jelly to hold it in place during assembly.
Fig 21: Placing Forward Clutch Hub Thrust Washer Onto Forward Hub And Ring Gear Assembly
Courtesy of FORD MOTOR CO.
20. Place the No. 8C forward clutch hub thrust washer onto the forward hub and ring gear assembly.
21. Place the forward hub and ring gear assembly into the intermediate brake drum and forward clutch cylinder assemblies.
    Fig 22: Placing Forward Hub And Ring Gear Assembly

    Courtesy of FORD MOTOR CO.
NOTE: Lightly lubricate the thrust bearing with petroleum jelly to hold it in place during assembly.
Fig 23: Installing Forward Planet Assembly
Courtesy of FORD MOTOR CO.
22. Verify the No. 10A forward planet assembly thrust bearing is installed.
23. Place the forward planet assembly into the forward hub and ring gear assembly.
    Fig 24: Placing Forward Planet Assembly Into Forward Hub

    Courtesy of FORD MOTOR CO.
NOTE: The thrust bearing notched inner race must face outward and the large outer diameter radius must face inward.
Fig 25: Installing Forward Clutch Thrust Bearing
Courtesy of FORD MOTOR CO.
24. Verify the No. 9B forward clutch thrust bearing is installed.
25. Align the notches with the lugs and position the input shell onto the intermediate brake drum. Rotate the input shell until fully seated.
    Fig 26: Aligning Notches With Lugs And Position

    Courtesy of FORD MOTOR CO.
NOTE: When installing the special tool, each leg of the tool must be rotated separately to engage notches on the input shell prior to tightening the top cross bar.
Fig 27: Installing Lower Direct Clutch Forward Clutch And Input Shell As An Assembly
Courtesy of FORD MOTOR CO.
26. Using the special tool, lower the direct clutch, forward clutch and input shell as an assembly into the case.
27. Install the intermediate band with the ear resting on the anchor pin.
    Fig 28: Installing Intermediate Band With Ear Resting On Anchor Pin

    Courtesy of FORD MOTOR CO.
NOTE: Prior to installation, lightly lubricate the piston seal with clean automatic transmission fluid.
Fig 29: Pressing Intermediate Band Servo Assembly Piston Into Case Bore
Courtesy of FORD MOTOR CO.
28. Gently press the intermediate band servo assembly piston into the case bore.
NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.
29. Install the intermediate clutch pack.
    1. intermediate clutch pressure plate
    2. Install the intermediate clutch pack, starting with an internal spline plate and alternating with external spline plates.
    3. Install the intermediate clutch pressure apply plate with blank area (no teeth) in the 6 o'clock and 12 o'clock positions.
       Fig 30: Installing Intermediate Clutch Pack

       Courtesy of FORD MOTOR CO.
NOTE: The following stack-up check measurement indicates not only the amount of space existing between the center support assembly and the intermediate brake drum, it also will indicate if the unit has been correctly built to this point.
30. Measure the stack up.
    1. Hold the thrust washer against the center support assembly.
    2. Extend the probe of the special tool into the hole until flush with the No. 6 center support thrust washer surface.
    3. Record this as reading 1.
       Fig 31: Holding Thrust Washer Against Center Support Assembly

       Courtesy of FORD MOTOR CO.
CAUTION: Do not misalign the center support in the case bore. This can cause case bore damage.
NOTE: Make sure the No. 6 center support thrust washer is on the center support prior to installation.
Fig 32: Installing Center Support Assembly
Courtesy of FORD MOTOR CO.
31. Install the center support assembly with the feed holes aligned in the case.
32. Make a second measurement after installation of the center support.
    1. Extend the probe of the special tool into the hole in the center support assembly until flush with the No. 6 center support thrust washer.
    2. Record this as reading 2.
       Fig 33: Installing Of Center Support

       Courtesy of FORD MOTOR CO.
33. Subtract reading 1 from reading 2. Record this as reading 3. If the final dimension is outside specified limits, this indicates that the transmission has been assembled incorrectly.
    Fig 34: Identifying Subtract Reading 1 From Reading 2 As Reading 3. Final Dimension Outside Specified Limits

    Courtesy of FORD MOTOR CO.
CAUTION: Do not tighten the bolts at this time. This could cause transmission failure.
Fig 35: Installing Two New Feedbolts
Courtesy of FORD MOTOR CO.
34. Loosely install two new feedbolts.
NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.
Fig 36: Installing Intermediate Clutch Return Spring
Courtesy of FORD MOTOR CO.
35. Install the intermediate clutch return spring with the dished surface inward and one spring leg in the 6 o'clock position.
CAUTION: Do not misalign the intermediate/overdrive cylinder assembly. This can damage the case bore.
Fig 37: Installing Intermediate/Overdrive Cylinder Assembly
Courtesy of FORD MOTOR CO.
36. Install the intermediate/overdrive cylinder assembly with the feed holes aligned with the holes in the case.
NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.
Fig 38: Installing Intermediate/Overdrive Cylinder Retaining Ring Over
Courtesy of FORD MOTOR CO.
37. Install the intermediate/overdrive cylinder retaining ring over the intermediate/overdrive cylinder with the ring opening in the 6 o'clock position to allow for the correct fluid drainback.
38. Install the special tool.
    1. Rotate the special tool clockwise to lock in place.
    2. Tighten the handle.
       Fig 39: Rotating Special Tool Clockwise-Lock In Place

       Courtesy of FORD MOTOR CO.
CAUTION: Make sure the snap ring is fully seated into the case. Transmission failure could occur.
NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.
Fig 40: Identifying Clock Position Viewed Looking Into Converter Housing With Top Of Transmission
Courtesy of FORD MOTOR CO.
39. Seat the intermediate/overdrive cylinder retaining ring into the case ring groove with the ring opening in the 6 o'clock position.
CAUTION: Do not tighten the bolts at this time. Transmission failure could occur.
Fig 41: Installing A New Intermediate/Overdrive Cylinder Feedbolt
Courtesy of FORD MOTOR CO.
40. Loosely install a new intermediate/overdrive cylinder feedbolt.
41. Loosen the center bolt and remove the special tool.
    Fig 42: Removing Special Tool

    Courtesy of FORD MOTOR CO.
NOTE: The number of plates in the clutch pack is vehicle-dependent.
NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.
42. Install the overdrive clutch pack.
    1. Install the overdrive clutch pack starting with a steel plate and alternating with friction plates.
    2. Install the overdrive clutch pressure plate with the dot facing outward and in the 12 o'clock position.
       Fig 43: Installing Overdrive Clutch Pressure Plate

       Courtesy of FORD MOTOR CO.
NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.
Fig 44: Installing Overdrive Clutch Pressure Plate Retainer Snap Ring
Courtesy of FORD MOTOR CO.
43. Install the overdrive clutch pressure plate retainer snap ring with the ring opening in the 6 o'clock position.
NOTE: The special tool must be used to install the coast clutch assembly or damage to the overdrive one-way clutch may occur.
NOTE: Use petroleum jelly to hold the No. 5 thrust bearing on the center shaft during assembly.
44. Using the special tool, install the coast clutch and No. 5 thrust bearing assembly.
    1. Install the No. 5 thrust bearing.
    2. Install the coast clutch assembly.
       Fig 45: Installing Coast Clutch And Thrust Bearing Assembly

       Courtesy of FORD MOTOR CO.

    Applications equipped with a PTO 

NOTE: The special tool must be used to install the coast clutch assembly or damage to the overdrive one-way clutch may occur.
NOTE: Use petroleum jelly to hold the No. 5 thrust bearing on the center shaft during assembly.
45. Using the special tool, install the coast clutch and No. 5 thrust bearing assembly.
    1. Install the No. 5 thrust bearing.
    2. Install the coast clutch assembly.
       Fig 46: Installing Coast Clutch And Thrust Bearing Assembly

       Courtesy of FORD MOTOR CO.

    All applications 

46. Check the stack-up clearance.
    • Using a feeler gauge, check the stack-up clearance in 3 places, 120 degrees apart.
    • If the clearance is not to specification, install the correct selective overdrive clutch pressure plate retainer snap ring and recheck the clearance. Refer to the Overdrive Clutch Pack .
      Fig 47: Checking Stack-Up Clearance Places Degrees Apart

      Courtesy of FORD MOTOR CO.
NOTE: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly.
Fig 48: Aligning Holes In Gasket With Holes In Case
Courtesy of FORD MOTOR CO.
47. Install the new pump gasket. Aligning the holes in the gasket with the holes in the case.
48. Install the input shaft with long-splined end first and install the special tool.
    Fig 49: Installing Input Shaft With Long-Splined End First And Install Special Tool

    Courtesy of FORD MOTOR CO.
NOTE: The No. 1 pump thrust washer is model dependent.
NOTE: Lightly lubricate the thrust washer and bearing with petroleum jelly to hold it in place during assembly.
Fig 50: Installing Pump Thrust Washer And Overdrive Sun Gear Thrust Bearing
Courtesy of FORD MOTOR CO.
49. Install the No. 1 pump thrust washer and the No. 2A overdrive sun gear thrust bearing.
CAUTION: Pump assemblies are vehicle-dependent. Using the wrong pump will cause transmission failure.
CAUTION: Fully seat the front pump assembly using hand pressure only. Do not use bolts to draw the front pump assembly into the case.
CAUTION: Tighten the bolts alternately to avoid possible damage.
NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.
Fig 51: Installing Front Pump Assembly With Filter Inlet Tube Bore
Courtesy of FORD MOTOR CO.
50. Install the front pump assembly with the filter inlet tube bore in the 6 o'clock position. Fully seat the front pump assembly using hand pressure only. When the pump is fully seated, remove the special tool.
CAUTION: Discard the old washers.
Fig 52: Installing Bolts With New Rubber-Coated Washers
Courtesy of FORD MOTOR CO.
51. Install the bolts with new rubber-coated washers. Tighten the bolts alternately in a crisscross pattern.
CAUTION: Remove the input shaft prior to rotating the transmission.
Fig 53: Removing Input Shaft
Courtesy of FORD MOTOR CO.
52. Remove the input shaft.
53. Using the special tool, install the manual control lever seal.
    Fig 54: Installing Manual Control Lever Seal

    Courtesy of FORD MOTOR CO.
54. Install the manual control lever shaft assembly.
    1. Install the manual control lever shaft assembly.
    2. Install and seat the manual lever shaft retaining pin below the case surface.
    NOTE: Use a crescent wrench on the manual control lever or outer flats of the manual control lever shaft assembly when installing the inner manual valve detent lever nut.
    3. Install the parking pawl actuating rod, the inner manual valve detent lever and the nut onto the manual control lever shaft assembly.
    NOTE: The manual control valve detent lever spring must be on the inner manual valve detent lever and the detent lever pin must align with the manual shift valve.
    Fig 55: Installing Manual Control Valve Detent Lever Spring
    Courtesy of FORD MOTOR CO.
    4. Install the manual control valve detent lever spring and the bolt.
55. Install the parking pawl.
    1. Install the parking pawl shaft.
    2. Install the parking pawl.
    3. Install the parking pawl return spring.
       Fig 56: Installing Parking Pawl

       Courtesy of FORD MOTOR CO.
CAUTION: The Torx® screw has a thread-locking compound. If the screw is removed, it must be discarded and a new one installed.
Fig 57: Installing Parking Pawl Abutment With A New Torx
Courtesy of FORD MOTOR CO.
56. If removed, install the parking pawl abutment with a new Torx® screw.
NOTE: Make sure the dimple on the parking guide support plate is facing inward and the parking pawl actuating rod is in the parking rod support plate slot.
57. Install the parking rod guide plate.
    1. Install the parking rod guide plate.
    2. Install the bolts.
       Fig 58: Installing Parking Rod Guide Plate

       Courtesy of FORD MOTOR CO.
58. Install a new orifice lube plug in the rear of the case. Using a 12 mm (0.48 in) socket, tap the orifice lube plug into the back of the transmission.
    Fig 59: Installing A New Orifice Lube Plug In Rear Of Case

    Courtesy of FORD MOTOR CO.
59. Check to make sure that the orifice lube plug is fully seated into the back of the transmission.
    Fig 60: Checking Make Sure Orifice Lube Plug Is Fully Seated Into Back Of Transmission

    Courtesy of FORD MOTOR CO.
CAUTION: The extension must have a shoulder or a boss cast in it to hold the orifice lube plug in the back of the case. If the wrong extension housing is used, the plug will fall out and cause transmission failure.
Fig 61: Inspecting Extension Housing For Correct
Courtesy of FORD MOTOR CO.
60. Inspect the extension housing for the correct application.
CAUTION: The extension must have a shoulder or a boss cast in it to hold the orifice lube plug in the back of the case. If the wrong extension housing is used, the plug may become loose and/or fall out and cause transmission damage.
NOTE: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly.
61. Install the new extension housing gasket.
    1. Verify that the extension has a shoulder cast in it.
    2. Install the new extension housing gasket.
       Fig 62: Installing New Extension Housing Gasket

       Courtesy of FORD MOTOR CO.
62. Install the extension housing, the eight bolts, and the stud.
    Fig 63: Installing Extension Housing

    Courtesy of FORD MOTOR CO.
CAUTION: Prior to installing the extension housing bushing, inspect the extension housing counter bore for burrs. If necessary, remove the burrs with an oil stone. Damage to the new bushing may occur.
NOTE: Extension housing bushing is vehicle-dependent.
Fig 64: Aligning Extension Housing Bushing In Extension Housing
Courtesy of FORD MOTOR CO.
63. Align the extension housing bushing in the extension housing so that the slots are in the 2 o'clock and 7 o'clock position.
64. Using the special tool, install the extension housing bushing.
    Fig 65: Installing Extension Housing Bushing

    Courtesy of FORD MOTOR CO.
NOTE: The extension housing seal is vehicle-dependent.
Fig 66: Installing A New Extension Housing Seal
Courtesy of FORD MOTOR CO.
65. Using the special tool, install a new extension housing seal.
66. Tighten the center support assembly, and the intermediate/overdrive cylinder assembly feedbolts.
    Fig 67: Identifying Intermediate/Overdrive Cylinder Assembly

    Courtesy of FORD MOTOR CO.
NOTE: The steel EPC check ball has a 6.35 mm (0.25 in) diameter and is smaller than the other check balls.
Fig 68: Installing Spring And Steel EPC Check Ball
Courtesy of FORD MOTOR CO.
67. Install the spring and the steel EPC check ball.
CAUTION: Use care not to damage the rubber check balls.
Fig 69: Installing Rubber Check Balls
Courtesy of FORD MOTOR CO.
68. Install the rubber check balls.
CAUTION: Using the incorrect gasket will cause damage to transmission.
Fig 70: Installing A New Separating Plate-To-Case Gasket On Separating Plate
Courtesy of FORD MOTOR CO.
69. Install a new separating plate-to-case gasket on the separating plate.
NOTE: Check the placement of the steel EPC check ball under separator plate.
Fig 71: Installing Valve Body Separator Plate
Courtesy of FORD MOTOR CO.
70. Install the valve body separator plate.
71. Install the separating plate reinforcing plate, with the stamped word "UP" visible, and install the bolts.
    Fig 72: Installing Separating Plate Reinforcing Plate

    Courtesy of FORD MOTOR CO.
CAUTION: Using the incorrect gasket will cause damage to the transmission.
Fig 73: Installing A New Main Control-To-Separating Plate Gasket
Courtesy of FORD MOTOR CO.
72. Install a new main control-to-separating plate gasket.
73. Install the solenoid screen assembly by pushing it in and rotating it to lock.
    Fig 74: Installing Solenoid Screen Assembly By Pushing It In And Rotating It-Lock

    Courtesy of FORD MOTOR CO.
NOTE: Prior to installing the solenoid body assembly, coat the case connector bore with petroleum jelly or equivalent.
Fig 75: Installing Solenoid Body Assembly With Nut And Torx Bolts Finger-Tight
Courtesy of FORD MOTOR CO.
74. Install the solenoid body assembly with the nut and the Torx® bolts finger-tight.
75. Install the main control valve body, aligning the manual shift valve with the inner manual valve detent lever. Install the nuts and the bolts finger-tight.
    Fig 76: Aligning Manual Shift Valve With Inner Manual Valve Detent Lever

    Courtesy of FORD MOTOR CO.
76. Install the accumulator body with the nuts and the bolts finger-tight.
    Fig 77: Installing Accumulator Body With Nuts

    Courtesy of FORD MOTOR CO.
77. Tighten all accumulator body, upper and lower control body and solenoid body nuts and bolts.
    Fig 78: Tightening All Accumulator Body Upper And Lower Control Body And Solenoid Body Nuts

    Courtesy of FORD MOTOR CO.
CAUTION: Mixing the 4x2-style and 4x4-style transmission fluid filters and transmission pan assembly components can cause transmission damage.
78. Select the appropriate 4x2-style or 4x4-style filter assembly and transmission pan.
    1. 4x2 filter and pan application.
    2. 4x4 filter and pan application.
       Fig 79: Identifying Transmission Fluid Filters And Transmission Pan Assembly

       Courtesy of FORD MOTOR CO.
CAUTION: Make sure the pump bore is clean and the old filter seal has been removed. Damage to the new filter and seal can occur.
NOTE: Prior to installation, lightly lubricate the seal with clean automatic transmission fluid.
Fig 80: Pressing A New Fluid Filter And Seal Assembly
Courtesy of FORD MOTOR CO.
79. Press a new fluid filter and seal assembly into the pump bore until seated.
NOTE: Do not discard the gasket unless damaged. This is a reusable gasket.
NOTE: Apply a light coat of petroleum jelly to hold the gasket to the fluid pan.
Fig 81: Positioning Gasket Onto Clean Fluid Pan
Courtesy of FORD MOTOR CO.
80. Position the gasket onto the clean fluid pan. Make sure the magnet is positioned over the dimple in the fluid pan.
CAUTION: Mixing the 4x2-style and 4x4-style transmission fluid filters and transmission pan assembly components can cause transmission damage.
Fig 82: Installing Correct Pan With Gasket For Application
Courtesy of FORD MOTOR CO.
81. Install the correct pan with gasket for this application. Alternately tighten the bolts.
82. With the transmission in NEUTRAL, install and adjust the digital transmission range (TR) sensor.
    1. Install the digital TR sensor.
    2. Loosely install the bolts.
       Fig 83: Installing Digital TR Sensor

       Courtesy of FORD MOTOR CO.
83. Using the special tool, align the TR sensor. The tool is designed to fit snug.
    Fig 84: Aligning TR Sensor

    Courtesy of FORD MOTOR CO.
84. Tighten the bolts and remove the special tool.
    Fig 85: Removing Special Tool

    Courtesy of FORD MOTOR CO.
85. Make sure that the cooler bypass valve (CBV) has been cleaned and flushed. Refer to COOLER BYPASS VALVE ASSEMBLY .
CAUTION: Failure to correctly install the new rubber-coated sealing washers will result in transmission fluid leaks.
86. Install the new rubber-coated sealing washers and the new cooler line case fittings.
    1. Install one rubber-coated sealing washers on each cooler line case fittings.
    2. Install new cooler line case fittings into their respective ends of the CBV assembly.
    3. Install one rubber-coated sealing washers on each cooler line case fittings.
       Fig 86: Installing One Rubber-Coated Sealing Washers On Cooler Line Case Fittings

       Courtesy of FORD MOTOR CO.
CAUTION: Do not overtighten.
Fig 87: Installing CBV With Front (Inlet) And Rear (Outlet) Cooler Line Case Fitting
Courtesy of FORD MOTOR CO.
87. Install the CBV with the front (inlet) and the rear (outlet) cooler line case fitting.
CAUTION: Use care when installing the sensor, damage to the O-ring could result in a leak.
88. Install the output shaft speed (OSS) sensor.
    1. Lubricate O-ring and install the OSS.
    2. Install the bolt.
       Fig 88: Installing Output Shaft Speed (OSS) Sensor

       Courtesy of FORD MOTOR CO.
CAUTION: Use care when installing the sensor, damage to the O-ring could result in a leak.
89. If removed, install the turbine shaft speed (TSS) sensor.
    1. Lubricate O-ring and install the TSS.
    2. Install the bolt.
       Fig 89: Installing Turbine Shaft Speed (TSS) Sensor

       Courtesy of FORD MOTOR CO.
NOTE: The input shaft is vehicle-dependent.
Fig 90: Installing Input Shaft With Long Splined End First
Courtesy of FORD MOTOR CO.
90. With the fluid pan facing down, install the input shaft with the long splined end first.
CAUTION: Do not damage the fluid pump gear O-ring when installing torque converter.
CAUTION: Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely. Do not damage the hub seal.
CAUTION: If the torque converter slides out, the hub seal may be damaged.
Fig 91: Installing Torque Converter
Courtesy of FORD MOTOR CO.
91. Lubricate the converter hub with clean automatic transmission fluid.
CAUTION: Use care when installing the torque converter to avoid damage to the front pump stator support seal.
NOTE: Check the converter crankshaft pilot for nicks or damaged surfaces that can cause interference when installing the transmission to the engine. Check the converter impeller hub for nicks or sharp edges that can damage the pump seal.
Fig 92: Installing Torque Converter
Courtesy of FORD MOTOR CO.
92. Using the special tools, install the torque converter. Push and rotate the converter onto the front pump assembly until it bottoms out.
93. Check the seating of the torque converter.
    1. Place the straightedge across the converter housing.
    2. Make sure there is a gap between the converter pilot face and the straightedge.
    3. Remove the special tools.
       Fig 93: Placing Straightedge Across Converter Housing

       Courtesy of FORD MOTOR CO.