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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 

    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.
  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the fan shroud bolts. Do not remove the fan shroud.
  3. Raise and support the vehicle. For additional information, refer to JACKING AND LIFTING .
  4. If transmission disassembly or installation of new transmission is necessary, drain the transmission fluid.
    • Install the drain plug when finished.
  5. Remove the 2 RH heat shield bolts and position the RH heat shield aside.
    Fig 1: Removing RH Heat Shield Bolts
    G03948756Courtesy of FORD MOTOR CO.
  6. Disconnect the 2 heated oxygen sensor electrical connectors.
    Fig 2: Locating Heated Oxygen Sensor Electrical Connector
    G03947157Courtesy of FORD MOTOR CO.
  7. Disconnect the 2 catalyst monitor sensor electrical connectors.
    Fig 3: Identifying Catalyst Monitor Sensor Electrical Connector
    G03947158Courtesy of FORD MOTOR CO.
  8. Remove the RH heat shield bolts.
    Fig 4: Removing RH Heat Shield Bolts
    G03947159Courtesy of FORD MOTOR CO.
  9. Remove the RH heat shield bolt and remove the heat shield.
    Fig 5: Removing RH Heat Shield Bolt And Remove Heat Shield
    G03947160Courtesy of FORD MOTOR CO.
  10. Remove the LH heat shield bolt.
    Fig 6: Locating LH Heat Shield Bolt
    G03947161Courtesy of FORD MOTOR CO.
  11. Remove the plastic shield on the right side of the crossmember near the fuel tank.
    Fig 7: Locating Plastic Shield On Right Side Of Crossmember Near Fuel Tank
    G03948762Courtesy of FORD MOTOR CO.
    12. NOTE: RH side shown, LH side similar.
    Fig 8: Removing Upper Crossmember Bolts (2 On Each Side)
    G03947163Courtesy of FORD MOTOR CO.
  12. Remove the 2 upper crossmember bolts (2 on each side).
  13. Remove the bolts, springs, flag nuts and separate the muffler from the converter.
    • Discard the gasket.
    • Discard the flag nuts.
      Fig 9: Removing Bolts, Springs, Flag Nuts And Separate Muffler From Converter
      G03947851Courtesy of FORD MOTOR CO.
    14. NOTE: LH side shown, RH similar.
    Fig 10: Locating Catalytic Converter-To-Manifold Nuts
    G03946966Courtesy of FORD MOTOR CO.
  14. Remove the 4 converter-to-manifold nuts.
  15. Install a suitable jackstand under the transfer case.
    Fig 11: Supporting Transfer Case With Suitable Jack Stand
    G03947504Courtesy of FORD MOTOR CO.
  16. Remove the RH side crossmember bolts.
    Fig 12: Locating RH Side Crossmember Bolts
    G03947164Courtesy of FORD MOTOR CO.
  17. Remove the LH side crossmember bolts.
    Fig 13: Removing LH Side Crossmember Bolts
    G03948767Courtesy of FORD MOTOR CO.
  18. Remove the transmission support insulator nuts and remove the crossmember.
    Fig 14: Identifying Transmission Support Insulator Nuts
    G03947166Courtesy of FORD MOTOR CO.
    19. NOTE: This step may require an assistant.
  19. Remove the transmission mounted exhaust hanger and the 3-way converter system.
    1. Remove the bolt and converter assembly.
    2. If required, remove the 2nd bolt and mount.
      Fig 15: Removing Bolt And Converter Assembly
      G03949284Courtesy of FORD MOTOR CO.
  20. Remove the shift cable and bracket.
    Fig 16: Identifying Shift Cable And Bracket
    G03947170Courtesy of FORD MOTOR CO.
  21. Position the manual lever out of park.
    Fig 17: Positioning Manual Lever Out Of Park
    G03948815Courtesy of FORD MOTOR CO.
  22. Index-mark the front axle pinion flange and the front driveshaft.
    Fig 18: Identifying Universal Joint Retainer Ring
    G03944118Courtesy of FORD MOTOR CO.
  23. Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.
    Fig 19: Identifying Index-Mark On Front Output Shaft Assembly
    G03912439Courtesy of FORD MOTOR CO.
  24. Remove and discard the bolts and washers.
    Fig 20: Removing Bolts And Washers
    G03947173Courtesy of FORD MOTOR CO.
  25. Remove and discard the bolts and universal joint retainers.
    Fig 21: Locating Universal Joint Retainers
    G03971114Courtesy of FORD MOTOR CO.
    26. CAUTION: Always disconnect the front driveshaft from the transfer case 1st. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.
    CAUTION: Tape the bearing cups to the driveshaft to prevent them from falling off of the spider.
    NOTE: The front driveshaft CV joint is not repairable.
    Fig 22: Removing Driveshaft
    G03947175Courtesy of FORD MOTOR CO.
  26. Remove the driveshaft.
    27. NOTE: The pinion flange is shown, transfer case flange is similar.
  27. Remove the rear driveshaft bolts.
    1. Mark the location of the flanges.
    2. Remove the 8 bolts.
      Fig 23: Removing Rear Driveshaft Bolts
      G03948772Courtesy of FORD MOTOR CO.
    28. NOTE: Do not use a hammer.
    Fig 24: Disconnecting Driveshaft Flange Yoke From Pinion Flange
    G03878446Courtesy of FORD MOTOR CO.
  28. Remove the driveshaft from the flange using a pry bar.

    29. 4.6L engine 

  29. Remove the electrical connector cover.
    Fig 25: Removing Electrical Connector Cover
    G03949222Courtesy of FORD MOTOR CO.
  30. Remove the starter wire and the positive battery cable.
    Fig 26: Removing Starter Wire And Positive Battery Cable
    G03985586Courtesy of FORD MOTOR CO.
  31. Remove the starter motor bolts and starter.
    Fig 27: Removing Starter Motor Bolts And Starter
    G03985585Courtesy of FORD MOTOR CO.
  32. Remove the flexplate cover.
    Fig 28: Removing Flexplate Cover
    G03948778Courtesy of FORD MOTOR CO.
  33. Remove the access cover.
    Fig 29: Removing Access Cover
    G03947881Courtesy of FORD MOTOR CO.
    34. NOTE: Make an identifying mark on the nut, stud and flexplate to allow for correct installation.
    Fig 30: Removing Torque Converter Nuts
    G03947882Courtesy of FORD MOTOR CO.
  34. Remove the 4 torque converter nuts.

    35. 4.0L engine 

  35. Remove the starter and position off to the side.
    Fig 31: Removing Starter And Position Off To Side
    G03949226Courtesy of FORD MOTOR CO.
    36. NOTE: Make an identifying mark on the nut, stud and flexplate to allow for correct installation.
    Fig 32: Removing Torque Converter Nuts
    G03948782Courtesy of FORD MOTOR CO.
  36. Remove the 4 torque converter nuts.
  37. Remove the lower transmission retaining bolts.
    Fig 33: Removing Lower Transmission Retaining Bolts
    G03949227Courtesy of FORD MOTOR CO.

    38. All vehicles 

  38. Lower the transmission to gain access to the sensor connectors and the transmission bolts.
  39. Disconnect the RH catalyst monitor connector and the fuel lines from the bracket.
    Fig 34: Locating Fuel Lines And RH Catalyst Monitor Connector Bracket
    G03947872Courtesy of FORD MOTOR CO.
  40. Disconnect the RH heated oxygen sensor from the transmission.
    Fig 35: Disconnecting RH Heated Oxygen Sensor From Transmission
    G03948785Courtesy of FORD MOTOR CO.
  41. If equipped, disconnect the shift motor electrical connector.
    Fig 36: Locating Shift Motor Electrical Connector And Wiring Harness Pin-Type Retainer
    G03947184Courtesy of FORD MOTOR CO.
  42. Disconnect the LH heated oxygen sensor and the harness clip from the transmission.
    Fig 37: Identifying Wire Harness Retainers
    G03948290Courtesy of FORD MOTOR CO.
  43. Disconnect the LH catalyst monitor connector from the transmission.
    Fig 38: Identifying LH Catalyst Monitor Connector Retainer At Transmission
    G03947871Courtesy of FORD MOTOR CO.
  44. Move the rubber boot back to gain access to the connector.
    Fig 39: Moving Rubber Boot Back To Gain Access To Connector
    G03947188Courtesy of FORD MOTOR CO.
  45. Disconnect the digital transmission range (TR) sensor connector.
    Fig 40: Locating Transmission Range (TR) Sensor Electrical Connector
    G03947189Courtesy of FORD MOTOR CO.
  46. Disconnect the turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor and intermediate shaft speed (ISS) sensor electrical connectors.
    Fig 41: Locating Electrical Connectors
    G03947190Courtesy of FORD MOTOR CO.
    47. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector.
    Fig 42: Identifying Solenoid Body Electrical Connector
    G03947191Courtesy of FORD MOTOR CO.
  47. Remove the screw from the solenoid body connector and disconnect the connector.
  48. Disconnect the harness retainers.
    Fig 43: Disconnecting Harness Retainers
    G03948792Courtesy of FORD MOTOR CO.
    49. CAUTION: Do not damage the cooler tubes. Hold the transmission case fittings with a wrench.
    Fig 44: Locating Transmission Cooler Tubes
    G03947193Courtesy of FORD MOTOR CO.
  49. Disconnect the transmission cooler tubes.
    50. WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.
  50. Support the transmission with a transmission jack.
  51. Remove the jackstand from under the transfer case.
    Fig 45: Supporting Transfer Case With Suitable Jack Stand
    G03947504Courtesy of FORD MOTOR CO.

    52. 4.6L engine 

    NOTE: RH side shown, LH side similar.
    Fig 46: Removing Front Crossmember Bolts And Crossmember
    G03949267Courtesy of FORD MOTOR CO.
  52. Remove the 4 front crossmember bolts and the crossmember.
  53. Remove the 7 engine-to-transmission retaining bolts.
    Fig 47: Locating Engine-To-Transmission Retaining Bolts
    G03947199Courtesy of FORD MOTOR CO.

    54. 4.0L engine 

  54. Remove the 6 engine-to-transmission retaining bolts and position the fuel line bracket aside.
    Fig 48: Removing Engine-To-Transmission Retaining Bolts And Position Fuel Line Bracket Aside
    G03949224Courtesy of FORD MOTOR CO.

    55. All vehicles 

  55. Lower the transmission and transfer case as an assembly from the vehicle.
  56. Install the special tool.
    Fig 49: Installing Special Tool
    G03948847Courtesy of FORD MOTOR CO.
    57. NOTE: If the transmission is being serviced, the transfer case will need to be removed.
  57. Remove the transfer case from the back of the transmission.
    • Remove the bolts and the bracket.
    • Disconnect the vent hose.
      Fig 50: Disconnecting Vent Hose
      G03948848Courtesy of FORD MOTOR CO.
  58. Carry out the transmission fluid cooler backflushing and cleaning if the transmission is being overhauled or installing a new or remanufactured transmission. For additional information, refer to TRANSMISSION FLUID COOLER - BACKFLUSHING AND CLEANING .
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