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Transmission - 4x4

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S) CHART

G03889235
 Retainer, Torque Converter
307-346 (T97T-7902-A)

    All vehicles 

    WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.
  1. If removed, install the transfer case to the back of the transmission, install the bracket and connect the vent hose.
    • Tighten to 41 Nm (30 lb-ft).
      Fig 1: Installing Transfer Case To Back Of Transmission
      G03948848Courtesy of FORD MOTOR CO.
  2. Remove the special tool.
    Fig 2: Removing Special Tool
    G03948847Courtesy of FORD MOTOR CO.
    3. WARNING: Make sure that the transmission and transfer case assembly are secured to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.
    NOTE: Rotate the torque converter so that the torque converter paint mark is in the 12 o'clock position.
  3. Raise and position the transmission and transfer case to the back of the engine.

    4. 4.6L engine 

  4. Install the 7 engine-to-transmission retaining bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 3: Locating Engine-To-Transmission Retaining Bolts
      G03947199Courtesy of FORD MOTOR CO.
  5. Install the 4 torque converter nuts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 4: Installing Torque Converter Nuts
      G03947882Courtesy of FORD MOTOR CO.
  6. Install the access cover.
    Fig 5: Installing Access Cover
    G03947881Courtesy of FORD MOTOR CO.
  7. Install the flexplate cover.
    • Tighten to 34 Nm (25 lb-ft).
      Fig 6: Installing Flexplate Cover
      G03948778Courtesy of FORD MOTOR CO.
  8. Install the starter.
    • Tighten to 24 Nm (18 lb-ft).
      Fig 7: Installing Starter
      G03985585Courtesy of FORD MOTOR CO.
  9. Install the starter motor electrical connectors.
    • Tighten the cable to 13 Nm (10 lb-ft).
    • Tighten the wire to 6 Nm (53 lb-in).
      Fig 8: Installing Starter Motor Electrical Connectors
      G03985586Courtesy of FORD MOTOR CO.
  10. Install the starter motor electrical connector cover.
    Fig 9: Installing Starter Motor Electrical Connector Cover
    G03949222Courtesy of FORD MOTOR CO.
    11. NOTE: RH side shown, LH side similar.
  11. Install the front crossmember and the 4 bolts (2 on each side).
    • Tighten to 70 Nm (52 lb-ft).
      Fig 10: Installing Front Crossmember
      G03949267Courtesy of FORD MOTOR CO.

    12. 4.0L engine 

  12. Position the fuel line bracket in place and install the 6 engine-to-transmission retaining bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 11: Positioning Fuel Line Bracket In Place
      G03949224Courtesy of FORD MOTOR CO.
  13. Install the 4 torque converter nuts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 12: Installing Torque Converter Nuts
      G03948782Courtesy of FORD MOTOR CO.
  14. Install the starter motor.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 13: Installing Starter Motor
      G03949226Courtesy of FORD MOTOR CO.
  15. Install the lower transmission retaining bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 14: Installing Lower Transmission Retaining Bolts
      G03949227Courtesy of FORD MOTOR CO.

    16. All vehicles 

  16. Install a jackstand under the transfer case.
    Fig 15: Supporting Transfer Case With Suitable Jack Stand
    G03947504Courtesy of FORD MOTOR CO.
  17. Remove the transmission jack from under the transmission.
    18. CAUTION: Use care not to bend or force the cooler tubes otherwise damage to the cooler tubes and the transmission can result.
  18. Install the transmission fluid cooler tubes.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 16: Locating Transmission Cooler Tubes
      G03947193Courtesy of FORD MOTOR CO.
  19. Connect the digital transmission range (TR) sensor connector.
    Fig 17: Locating Transmission Range (TR) Sensor Electrical Connector
    G03947189Courtesy of FORD MOTOR CO.
  20. Move the rubber boot back over the connector.
    Fig 18: Moving Rubber Boot Back Over Connector
    G03947188Courtesy of FORD MOTOR CO.
  21. Connect the LH heated oxygen sensor (HO2S) to the transmission and install the wire harness retainer.
    Fig 19: Identifying Wire Harness Retainers
    G03948290Courtesy of FORD MOTOR CO.
  22. Position the wire harness and install the retainers.
    Fig 20: Positioning Wire Harness And Install Retainers
    G03949232Courtesy of FORD MOTOR CO.
    23. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification.
    NOTE: Always install new O-ring seals on the vehicle harness connector.
    NOTE: Clean the area around connector to prevent contamination of the solenoid body connector.
    NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
  23. Install and lubricate new O-ring seals on the transmission connector and connect the connector.
    • Tighten to 5 Nm (44 lb-in).
      Fig 21: Identifying Solenoid Body Electrical Connector
      G03947191Courtesy of FORD MOTOR CO.
  24. Connect the LH catalyst monitor connector to the transmission.
    Fig 22: Identifying LH Catalyst Monitor Connector Retainer At Transmission
    G03947871Courtesy of FORD MOTOR CO.
  25. Connect the RH heated oxygen sensor (HO2S) to the transmission.
    Fig 23: Connecting RH Heated Oxygen Sensor To Transmission
    G03948785Courtesy of FORD MOTOR CO.
  26. Connect the fuel lines and the RH catalyst monitor connector to the bracket.
    Fig 24: Locating Fuel Lines And RH Catalyst Monitor Connector Bracket
    G03947872Courtesy of FORD MOTOR CO.
  27. Connect the turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor, and intermediate shaft speed (ISS) sensor electrical connectors.
    Fig 25: Locating Electrical Connectors
    G03947190Courtesy of FORD MOTOR CO.
    28. NOTE: This step may require an assistant.
    Fig 26: Locating Catalytic Converter-To-Manifold Nuts
    G03946966Courtesy of FORD MOTOR CO.
  28. Position the catalytic converter assembly with heat shield and loosely install the 4 converter-to-manifold nuts.
  29. Install the rear transmission mount bolts.
    1. Position the rear transmission mount and exhaust hanger.
    2. Install the rear mount bolts.
      • Tighten to 90 Nm (66 lb-ft).
        Fig 27: Installing Rear Transmission Mount Bolts
        G03949284Courtesy of FORD MOTOR CO.
    30. NOTE: LH side shown, RH side similar.
    Fig 28: Locating Heated Oxygen Sensor Electrical Connector
    G03947157Courtesy of FORD MOTOR CO.
  30. Connect the 2 heated oxygen sensor electrical connectors.
  31. Connect the 2 catalyst monitor sensor electrical connectors.
    Fig 29: Identifying Catalyst Monitor Sensor Electrical Connector
    G03947158Courtesy of FORD MOTOR CO.
  32. Position the crossmember in place and loosely install the 2 nuts to hold up the crossmember.
    Fig 30: Installing Hold Up Crossmember
    G03948310Courtesy of FORD MOTOR CO.
  33. Install the RH side crossmember bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 31: Locating RH Side Crossmember Bolts
      G03947164Courtesy of FORD MOTOR CO.
  34. Install the LH side crossmember bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 32: Installing LH Side Crossmember Bolts
      G03948767Courtesy of FORD MOTOR CO.
  35. Remove the jackstand.
    Fig 33: Supporting Transfer Case With Suitable Jack Stand
    G03947504Courtesy of FORD MOTOR CO.
    36. NOTE: RH side shown, LH side similar.
  36. Install the 2 upper crossmember bolts (2 on each side).
    • Tighten to 70 Nm (52 lb-ft).
      Fig 34: Installing Upper Crossmember Bolts
      G03947163Courtesy of FORD MOTOR CO.
  37. Tighten the rear transmission mount nuts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 35: Identifying Transmission Support Insulator Nuts
      G03947166Courtesy of FORD MOTOR CO.
  38. Install the RH heat shield and bolts.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 36: Installing RH Heat Shield And Bolts
      G03947159Courtesy of FORD MOTOR CO.
  39. Install the LH heat shield bolts.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 37: Locating LH Heat Shield Bolt
      G03947161Courtesy of FORD MOTOR CO.
  40. Install the plastic shield on the right side of the crossmember near the fuel tank.
    • Tighten to 9 Nm (80 lb-in).
      Fig 38: Locating Plastic Shield On Right Side Of Crossmember Near Fuel Tank
      G03948762Courtesy of FORD MOTOR CO.
  41. Tighten the 4 converter-to-manifold nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 39: Locating Catalytic Converter-To-Manifold Nuts
      G03946966Courtesy of FORD MOTOR CO.
  42. Using a new gasket, install the converter-to-muffler pipe and the heat shield. Install the bolts, springs and flag nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 40: Installing Converter-To-Muffler Pipe And Heat Shield
      G03947851Courtesy of FORD MOTOR CO.
  43. If equipped, connect the shift motor electrical connector.
    Fig 41: Locating Shift Motor Electrical Connector And Wiring Harness Pin-Type Retainer
    G03947184Courtesy of FORD MOTOR CO.
    44. CAUTION: The can (domed CV joint housing cover) is pressed into the CV joint housing at the factory. When housed correctly, the can will appear as shown in the cut-away illustration , top box in Fig 42. Do not reseat the can in the CV joint housing if the can's flange is above the CV joint housings shown in the cut-away illustration, bottom box in Fig 42. Install a new driveshaft.
    Fig 42: Installing Driveshaft
    G03944122Courtesy of FORD MOTOR CO.
  44. Verify that the can flange is housed correctly it the CV joint housing as shown in the cut-away illustration, top box in Fig 42. Install a new driveshaft if the can flange is not housed correctly.
    45. CAUTION: Always connect the front driveshaft to the axle 1st. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.
    NOTE: Align the index marks.
  45. Install the driveshaft.
    46. CAUTION: Tighten the bolts evenly in a cross pattern or damage will occur to the CV joint.
    NOTE: Install new washers and bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.
  46. Install the new washers and bolts. Tighten the bolts evenly in a cross pattern.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 43: Installing Washers And Bolts
      G03947173Courtesy of FORD MOTOR CO.
  47. Verify that the CV joint has seated squarely in the transfer case flange.
    • Check that the space between the end of the CV joint cap and the end of the transfer case flange is equal from the top to the bottom of the 2 components.
    • Rotate the driveshaft 1/4 turn.
    • Check that the space between the end of the CV joint cap and the end of the transfer case flange is equal from the top to the bottom of the 2 components.
    • Repeat this procedure several times.
    • If the space if not equal at any point in the attachment, remove and reinstall the driveshaft as described in this procedure.
      Fig 44: Rotating Driveshaft 1/4 Turn
      G03949301Courtesy of FORD MOTOR CO.
    48. NOTE: Install new universal joint retainers and bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.
  48. Install the new universal joint retainer and bolts.
    • Tighten to 18 Nm (13 lb-ft).
      Fig 45: Locating Universal Joint Retainers
      G03971114Courtesy of FORD MOTOR CO.
    49. CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with Threadlock and Sealer TA-25 or equivalent meeting Ford specification WSK-M2G351-A5.
    CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in a cross pattern as shown in Fig 46.
  49. Install the rear driveshaft and the 8 bolts.
    1. Align the index marks.
    2. Install the bolts.
      • Tighten to 112 Nm (83 lb-ft).
        Fig 46: Installing Rear Driveshaft Bolts
        G03878447Courtesy of FORD MOTOR CO.
  50. Install the shift cable and bracket.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 47: Installing Shift Cable And Bracket
      G03949256Courtesy of FORD MOTOR CO.
  51. Use the following guidelines for installing 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 in-line 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. For additional information, refer to TRANSMISSION FLUID IN-LINE FILTER .
    52. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they can experience slightly different upshifts (either soft or firm) and that this is a temporary condition and will eventually return to normal operating condition.
  52. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  53. Position the fan shroud and install the bolts.
  54. Carry out the fluid level check. For additional information, refer to TRANSMISSION FLUID LEVEL CHECK .
  55. Verify that the shift cable is correctly adjusted. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS .
  56. Check the operation of the transmission and inspect for leaks
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