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Transmission - Diesel Engines: Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Prior to installation of a new or overhauled transmission, a new transmission fluid cooler remote filter must be installed.
    CAUTION: Prior to installation of a new or overhauled transmission, the fluid cooler lines must be cleaned.
  1. Install a new transmission fluid cooler remote filter. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING .
  2. Loosely position the fluid cooler tubes in place.
    Fig 1: Identifying Fluid Cooler Tubes
    G03381474Courtesy of FORD MOTOR CO.
  3. Loosely install the fluid filter bracket and bolt.
    Fig 2: Installing Fluid Filter Bracket And Bolt
    G03381475Courtesy of FORD MOTOR CO.
  4. Tighten the transmission fluid cooler tube nuts and remove the bracket bolt.
    Fig 3: Tightening Transmission Fluid Cooler Tube Nuts And Bracket Bolt
    G03381476Courtesy of FORD MOTOR CO.
  5. If equipped, install the transmission-mounted parking brake.
    1. Install a new transmission-mounted parking brake gasket.
    2. Keeping the vent in an upward position, install the transmission-mounted parking brake assembly.
    3. Install the transmission-mounted parking retaining bolts.
      Fig 4: Installing Transmission-Mounted Parking Retaining Bolts
      G03381477Courtesy of FORD MOTOR CO.
    6. CAUTION: Prior to the installation of the assembly, the torque converter pilot hub must be correctly lubricated or damage to the torque converter or the engine crankshaft can occur.
    Fig 5: Lubricating Torque Converter Pilot Hub With Multi-Purpose Grease
    G03381478Courtesy of FORD MOTOR CO.
  6. Lubricate the torque converter pilot hub with multi-purpose grease.
  7. Rotate the torque converter so the orange or green paint daub is in the 12 o'clock position.
  8. If the special tool has not been installed during the assembly of the transmission, install the special tool 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 special tool.
    Fig 6: Installing Special Tool To Hold Torque Converter
    G03381479Courtesy of FORD MOTOR CO.
  9. Position the transmission in place. While raising the transmission up into the engine compartment, align the fluid filler tube with the stub tube on the transmission using the 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.

    Fig 7: Aligning Fluid Filler Tube With Stub Tube
    G03381480Courtesy of FORD MOTOR CO.
  10. Position the electrical wiring harness bracket in place and install the eight transmission-to-engine bolts.
    Fig 8: Installing Eight Transmission-To-Engine Bolts
    G03381481Courtesy of FORD MOTOR CO.
  11. Connect the wire harness to the bracket.
    Fig 9: Connecting Wire Harness To Bracket
    G03381482Courtesy of FORD MOTOR CO.
  12. Using the special tool, rotate the crankshaft to gain access to the torque converter studs.
    Fig 10: Rotating Crankshaft To Gain Access To Torque Converter Studs
    G03381483Courtesy of FORD MOTOR CO.
  13. Install the new torque converter-to-flexplate nuts.
    Fig 11: Installing Torque Converter-To-Flexplate Nuts
    G03381484Courtesy of FORD MOTOR CO.
  14. Install the cylinder block opening cover.
    Fig 12: Installing Cylinder Block Opening Cover
    G03381485Courtesy of FORD MOTOR CO.
  15. Install the wire harness retaining clip into the transmission on the LH side.
    Fig 13: Installing Wire Harness Retaining Clip Into Transmission On LH Side
    G03381486Courtesy of FORD MOTOR CO.
  16. Connect the wire harness on the RH side of the transmission.
    Fig 14: Connecting Wire Harness On RH Side Of Transmission
    G03381487Courtesy of FORD MOTOR CO.
  17. Install the oil filter housing.
    Fig 15: Installing Oil Filter Housing
    G03381488Courtesy of FORD MOTOR CO.
  18. Connect the oil cooler lines.
    Fig 16: Connecting Oil Cooler Lines
    G03381489Courtesy of FORD MOTOR CO.
  19. Install the transmission mount.
    Fig 17: Installing Transmission Mount
    G03381490Courtesy of FORD MOTOR CO.
  20. Position the crossmember to the transmission mount and loosely install the nut.
    Fig 18: Positioning Crossmember To Transmission Mount
    G03381491Courtesy of FORD MOTOR CO.
  21. Install the LH crossmember bracket.
    Fig 19: Installing LH Crossmember Bracket
    G03381492Courtesy of FORD MOTOR CO.
  22. Install the LH crossmember nuts.
    Fig 20: Installing LH Crossmember Nuts
    G03381493Courtesy of FORD MOTOR CO.
  23. Install the RH crossmember bracket.
    Fig 21: Installing RH Crossmember Bracket
    G03381494Courtesy of FORD MOTOR CO.
  24. Install the RH crossmember nuts.
    Fig 22: Installing RH Crossmember Nuts
    G03381495Courtesy of FORD MOTOR CO.
  25. Tighten the rear insulator nuts.
    Fig 23: Tightening Rear Insulator Nuts
    G03381496Courtesy of FORD MOTOR CO.
  26. Connect the output shaft speed (OSS) sensor electrical connector.
    Fig 24: Connecting Output Shaft Speed (OSS) Sensor Electrical Connector
    G03381497Courtesy of FORD MOTOR CO.
  27. Connect the intermediate shaft and turbine shaft combination speed sensor electrical connector.
    Fig 25: Connecting Intermediate Shaft And Turbine Shaft Combination Speed Sensor Electrical Connector
    G03381498Courtesy of FORD MOTOR CO.
  28. Connect the solenoid body electrical connector.
    Fig 26: Connecting Solenoid Body Electrical Connector
    G03381499Courtesy of FORD MOTOR CO.
  29. Connect the shift cable.
    1. Install the cable housing bracket with one stud bolt and one bolt.
    2. Install the bolt and nut for the filter housing and bracket.
    3. Connect the wire harness to the bracket.
    4. Install the shift cable to the manual lever.
      Fig 27: Installing Shift Cable To Manual Lever
      G03381500Courtesy of FORD MOTOR CO.
    30. NOTE: Install a new remote filter element.
    Fig 28: Installing Fluid Cooler Lines To Filter Housing
    G03381501Courtesy of FORD MOTOR CO.
  30. Install the fluid cooler lines to the filter housing.
  31. Connect the retainers to the remote filter housing.
    Fig 29: Connecting Retainers To Removing Filter Housing
    G03381502Courtesy of FORD MOTOR CO.
  32. If equipped, install the wire harness and install the two retaining clips to the rear of the crossmember.
    33. Fig 30: Installing Retaining Clips To Rear Of Crossmember
    G03381503Courtesy of FORD MOTOR CO.
  33. If equipped, connect the transmission-mounted parking brake.
    1. Install the parking cable into the bracket.
    2. Position the cable end onto the lever.
    3. Install the retaining pin and clip.
    4. Install the return spring.
      Fig 31: Identifying Parking Cable Into Bracket And Retaining Pin And Clip
      G03381504Courtesy of FORD MOTOR CO.
  34. Install the rear driveshaft. For additional information, refer to DRIVESHAFT .
    35. CAUTION: If installing a newly overhauled or a new transmission, a new transmission fluid cooler remote filter must be installed. Otherwise transmission failure can occur.
  35. Install a new transmission fluid cooler remote filter. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING .
  36. Use the following guidelines for 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 inline 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.

  37. Adjust the shift linkage. Verify that the vehicle starts in PARK and NEUTRAL and the REVERSE lamps illuminate in REVERSE. For additional information, refer to TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS .
  38. Install the fluid level indicator.
  39. 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 fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).
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