All transmissions

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Mount the transmission case into a suitable stand.
If removed, use the special tool to install the short fluid inlet tube.

Fig 1: Installing Short Fluid Inlet Tube
Courtesy of FORD MOTOR CO.
If removed, use the special tool to install a new Teflon® seal retainer.
- Install two new Teflon® seals.
  
  Fig 2: Installing Teflon® Seals
  Courtesy of FORD MOTOR CO.

NOTE: Coat the reverse clutch piston seals with petroleum jelly.

Fig 3: Installing Reverse Clutch Piston In Case

Courtesy of FORD MOTOR CO.

Install the reverse clutch piston in the case until it is fully seated in the case.
Install the reverse clutch return spring assembly.

Fig 4: Installing Reverse Clutch Return Spring Assembly
Courtesy of FORD MOTOR CO.

WARNING: Do not overcompress the return spring, damage to the spring will occur.

Fig 5: Installing Reverse Clutch Return Spring Snap Ring

Courtesy of FORD MOTOR CO.

Using the special tool, install the reverse clutch return spring snap ring.

NOTE: The use of petroleum jelly will hold the No. 17 thrust bearing or washer in place during assembly.

Fig 6: Installing Park Gear Thrust Bearing And Washer

Courtesy of FORD MOTOR CO.

For vehicles equipped with a slip yoke, install the No. 17 park gear thrust bearing. For vehicles equipped with a fixed yoke, install the No. 17 park gear thrust washer.

WARNING: Be careful when installing the output shaft not to damage the seals or transmission internal leakage could occur.

Fig 7: Installing Output Shaft

Courtesy of FORD MOTOR CO.

Install the output shaft.

CAUTION: The Torx® screw has a threadlocking compound. If the screw is removed, it must be discarded and a new screw installed.

Fig 8: Installing Parking Pawl Abutment With Torx® Screw

Courtesy of FORD MOTOR CO.

If removed, install the parking pawl abutment with a new Torx® screw.
Install the parking pawl.
1. Install the parking pawl shaft.
2. Install the parking pawl.
3. Install the parking pawl return spring.
  
  Fig 9: Installing Parking Pawl
  Courtesy of FORD MOTOR CO.

NOTE: Make sure the dimple on the parking guide support plate is facing inward.

Install the parking rod guide plate.
1. Install the parking rod guide plate.
2. Install the bolts.
  
  Fig 10: Installing Parking Rod Guide Plate
  Courtesy of FORD MOTOR CO.
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. Check to make sure that the orifice lube plug is fully seated into the back of the transmission.

Fig 11: Installing Orifice Lube Plug In Rear Of Case
Courtesy of FORD MOTOR CO.
Install a new extension housing gasket.

Fig 12: Installing Extension Housing Gasket
Courtesy of FORD MOTOR CO.
Install the extension housing.

Fig 13: Installing Extension Housing
Courtesy of FORD MOTOR CO.
Using the special tool, install a new manual control lever seal.

Fig 14: Installing Manual Control Lever Seal
Courtesy of FORD MOTOR CO.
Install the transmission range sensor, park rod assembly and loosely install the bolts.

Fig 15: Installing Transmission Range Sensor, Park Rod Assembly
Courtesy of FORD MOTOR CO.
Install the manual control lever.

Fig 16: Installing Manual Control Lever
Courtesy of FORD MOTOR CO.
Install the roll pin into the case.

Fig 17: Installing Roll Pin Into Case
Courtesy of FORD MOTOR CO.
Install a new roll pin. Leave 2 mm (0.08 in) of the pin exposed.

Fig 18: Installing Roll Pin
Courtesy of FORD MOTOR CO.
Tighten the transmission range sensor bolts.

Fig 19: Tightening Transmission Range Sensor Bolts
Courtesy of FORD MOTOR CO.

Fixed yoke transmissions
Use the special tool and install a new extension housing seal.

Fig 20: Installing Extension Housing Seal
Courtesy of FORD MOTOR CO.
Inspect the new output shaft nut O-ring for cuts. If there is any damage to the nut or seal, a new nut must be installed.

Fig 21: Inspecting Output Shaft Nut O-Ring
Courtesy of FORD MOTOR CO.
Using the special tool, install the output shaft nut.

Fig 22: Installing Output Shaft Nut
Courtesy of FORD MOTOR CO.
If the vehicle is equipped with a fixed yoke, install the output flange.
1. Install the flange.
2. Install a new bolt.
  
  Fig 23: Installing Output Flange And Bolt
  Courtesy of FORD MOTOR CO.
Slip yoke transmissions
If removed, install a new output shaft bushing using the special tool.

Fig 24: Installing Output Shaft Bushing
Courtesy of FORD MOTOR CO.
Install a new output shaft seal using the special tool.

Fig 25: Installing Output Shaft Seal
Courtesy of FORD MOTOR CO.

All transmissions
Install the No. 16 bearing and race.

Fig 26: Installing Bearing And Race
Courtesy of FORD MOTOR CO.
Install the ring gear, hub and the No. 15 hub bearing.

Fig 27: Installing Ring Gear, Hub And Hub Bearing
Courtesy of FORD MOTOR CO.
Install the reverse carrier and hub assembly.

Fig 28: Installing Reverse Carrier And Hub Assembly
Courtesy of FORD MOTOR CO.
Install the low/reverse clutch plates.
- Start with a steel plate on the bottom, followed by a friction plate.
- Alternately stack the remaining steel and friction plates.
- Add the pressure plate (low/reverse one way clutch) on the last friction plate with THIS SIDE UP facing upward.
  
  Fig 29: Installing Low/Reverse Clutch Plates
  Courtesy of FORD MOTOR CO.

CAUTION: Do not apply air pressure to move the low/reverse piston without first installing the friction plates and the snap ring, damage to the snap ring will occur.

Install the new snap ring. Make sure the snap ring opening is in the one o'clock position, between 2 teeth on the case.
- Check the function of the reverse clutch by applying air to the correct passage (through the case valve body worm trail) for the reverse clutch.
  
  Fig 30: Installing Snap Ring
  Courtesy of FORD MOTOR CO.
Using the special tools, install the forward geartrain as an assembly.

Fig 31: Installing Forward Geartrain
Courtesy of FORD MOTOR CO.
Install the intermediate clutch pressure plate.
- Position the intermediate clutch pressure plate in the case with the stepped edge facing downward.
  
  Fig 32: Installing Intermediate Clutch Pressure Plate
  Courtesy of FORD MOTOR CO.
Install the intermediate clutch plates, starting with a friction plate.

Fig 33: Installing Intermediate Clutch Plates
Courtesy of FORD MOTOR CO.
Install the center support.

Fig 34: Installing Center Support
Courtesy of FORD MOTOR CO.
Loosely install the feed bolts.

Fig 35: Installing Feed Bolts
Courtesy of FORD MOTOR CO.
Using the special tool, install the center support snap ring.
- The snap ring should be installed with the flat edge facing downward. The gap in the snap ring should be facing in the six o'clock position. Tap the snap ring securely into the case
  
  Fig 36: Installing Center Support Snap Ring
  Courtesy of FORD MOTOR CO.
Tighten the feed bolts.

Fig 37: Tightening Feed Bolts
Courtesy of FORD MOTOR CO.
Install the No. 5 thrust bearing onto the center support.

Fig 38: Installing Thrust Bearing Onto Center Support
Courtesy of FORD MOTOR CO.
Install the center shaft and ring gear.

Fig 39: Installing Center Shaft And Ring Gear
Courtesy of FORD MOTOR CO.
Install the No. 4 thrust bearing onto the center shaft.

Fig 40: Installing Thrust Bearing Onto Center Shaft
Courtesy of FORD MOTOR CO.
Using the special tool, install the coast clutch assembly and overdrive carrier.

Fig 41: Installing Coast Clutch Assembly And Overdrive Carrier
Courtesy of FORD MOTOR CO.
Install the overdrive clutch assembly snap ring with the gap in the six o'clock position.

Fig 42: Installing Overdrive Clutch Assembly Snap Ring
Courtesy of FORD MOTOR CO.
For non-PTO applications, install the overdrive pressure plate with the notches facing up.

Fig 43: Installing Overdrive Pressure Plate
Courtesy of FORD MOTOR CO.
For vehicles equipped with a PTO, install the overdrive pressure plate.
1. Install the larger tab positioned at the top of the case.
2. Install the square end of the plate in the bottom of the case.
  - The PTO pressure plate anti rotation tab is installed into the 6 o'clock position of the snap ring gap.
    
    Fig 44: Identifying PTO Pressure Plate
    Courtesy of FORD MOTOR CO.
Install the overdrive clutch.
- Start with a friction plate, alternating with a steel plate.
  
  Fig 45: Installing Overdrive Clutch
  Courtesy of FORD MOTOR CO.
Install a new pump gasket.

Fig 46: Installing Pump Gasket
Courtesy of FORD MOTOR CO.
Install the No. 2 thrust bearing.

Fig 47: Installing Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the input shaft into the case.

Fig 48: Installing Input Shaft Into Case
Courtesy of FORD MOTOR CO.
Install the special tools into the case in order to install the pump.

Fig 49: Installing Special Tools Into Case
Courtesy of FORD MOTOR CO.
Check to make sure that the No. 1 thrust washer is installed on the pump stator.
Using the special tools, install the pump assembly.

Fig 50: Installing Pump Assembly
Courtesy of FORD MOTOR CO.
Install new retaining bolts.

Fig 51: Installing Retaining Bolts
Courtesy of FORD MOTOR CO.
Install a new main control body gasket.

Fig 52: Installing Main Control Body Gasket
Courtesy of FORD MOTOR CO.
Using the special tools, check the function of each clutch. Apply 20 psi (137.9 kPa) of air to each port.

Fig 53: Checking Function Of Clutches
Courtesy of FORD MOTOR CO.
Install the forward clutch orifice in place on the top of the forward clutch feed bolt.

Fig 54: Installing Forward Clutch Orifice
Courtesy of FORD MOTOR CO.
Using the special tools, install the solenoid body and loosely install the bolts.
- While installing the solenoid body, align the manual valve.
  
  Fig 55: Installing Solenoid Body Bolts
  Courtesy of FORD MOTOR CO.
Tighten all the bolts in the sequence shown.

Fig 56: Tightening All Bolts
Courtesy of FORD MOTOR CO.
Connect the transmission range sensor connector.

Fig 57: Connecting Transmission Range Sensor Connector
Courtesy of FORD MOTOR CO.

NOTE: Prior to installing the fluid filter, make sure that the old seal is not stuck in the case.

Fig 58: Installing Transmission Fluid Filter

Courtesy of FORD MOTOR CO.

Install a new transmission fluid filter.

NOTE: Do not discard the fluid pan gasket. It is reusable.

Fig 59: Installing Transmission Fluid Pan Gasket To Fluid Pan

Courtesy of FORD MOTOR CO.

Install the transmission fluid pan gasket to the fluid pan. Make sure the magnet is positioned over the dimple in the fluid pan.
Install the transmission fluid pan.

Fig 60: Installing Transmission Fluid Pan
Courtesy of FORD MOTOR CO.
Install the intermediate shaft and turbine shaft speed (TSS) sensor.

Fig 61: Installing Intermediate Shaft And Turbine Shaft Speed Sensor
Courtesy of FORD MOTOR CO.
Install the output shaft speed (OSS) sensor.

Fig 62: Installing Output Shaft Speed Sensor
Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the fluid pump gear O-ring when installing the 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 63: Lubricating Converter Hub With Clean Automatic Transmission Fluid

Courtesy of FORD MOTOR CO.

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 64: Installing Torque Converter

Courtesy of FORD MOTOR CO.

Using the special tools, install the torque converter. Push and rotate the converter onto the front pump assembly until it bottoms out.
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 65: Illustration Steps-1, 2 and 3
  Courtesy of FORD MOTOR CO.
Use the special tool to hold the torque converter in place when installing the transmission.

Fig 66: Holding Torque Converter By Special Tool
Courtesy of FORD MOTOR CO.