Section 303 (Overhaul - Automatic Transmission): Installation: Transmission

4X4 Vehicles 

1. Install the vent tube assembly.
   Fig 1: Installing Vent Tube Assembly

   Courtesy of FORD MOTOR CO.

   All Vehicles 

WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions may result in personal injury.
2. Raise and position the transmission.
3. Remove the special tool.
   Fig 2: Removing Special Tool

   Courtesy of FORD MOTOR CO.

   4.0L SOHC Engine 

NOTE: Align the flexplate to the converter marks made at removal.
Fig 3: Locating Transmission-To-Engine Screws
Courtesy of FORD MOTOR CO.
4. Install the transmission-to-engine screws.
   1. Install 2 M10 x 40 mm (1.6 in) screws.
   2. Install 4 M10 x 50 mm (2 in) screws.
   3. Install 2 M10 x 75 mm (3 in) screws.

   2.3L & 3.0L Engines 

NOTE: Align the flexplate to the converter marks made at removal.
Fig 4: Locating Transmission-To-Engine Screws
Courtesy of FORD MOTOR CO.
5. Install the screws.
   1. Install 1 M10 x 40 mm (1.6 in) screw.
   2. Install 4 M10 x 50 mm (2 in) screws.
   3. Install 2 M10 x 75 mm (3 in) screws.
6. Install the upper fluid filler tube and bracket screw.
   1. Install the upper filler tube.
   2. Install the M10 x 40 mm (1.6 in) bracket screw.
   Fig 5: Installing Upper Fluid Filler Tube & Bracket Screw

   Courtesy of FORD MOTOR CO.

   2.3L Engine 

7. Install the lower transmission-to-engine screws.
   Fig 6: Installing Lower Transmission-To-Engine Screws

   Courtesy of FORD MOTOR CO.
8. Install the HO2S connector bracket.
   Fig 7: Installing HO2S Connector Bracket

   Courtesy of FORD MOTOR CO.
9. Install the rear engine cover plate.
   Fig 8: Installing Rear Engine Cover Plate

   Courtesy of FORD MOTOR CO.

   4X4 Vehicles 

10. Install the transfer case. For additional information, refer to TRANSFER CASE - AUTOMATIC SHIFT .

    All Vehicles 

11. Install the screws.
    1. Install the exhaust bracket.
    2. Install the screws.
    Fig 9: Installing Transmission Mount/Exhaust Bracket Screws

    Courtesy of FORD MOTOR CO.

    4X2 Vehicles 

12. Install the crossmember.
    1. Position the crossmember.
    2. Install the eight bolts (four each side).
    Fig 10: Installing Crossmember (4X2)

    Courtesy of FORD MOTOR CO.

    4X4 Vehicles 

13. Install the crossmember.
    1. Position the crossmember.
    2. Install the six crossmember bolts (three each side).
    Fig 11: Installing Crossmember (4X4)

    Courtesy of FORD MOTOR CO.

    All Vehicles 

14. Install the transmission mount into the crossmember and tighten the nuts.
    Fig 12: Installing Transmission Mount Nuts

    Courtesy of FORD MOTOR CO.

    3.0L Engines 

15. Install the rear vibration damper.
    Fig 13: Installing Rear Vibration Damper

    Courtesy of FORD MOTOR CO.

    All Vehicles 

16. Remove the High-Lift Transmission Jack.
CAUTION: Care should be taken not to bend or damage the cooler lines.
Fig 14: Installing Transmission Cooler Lines
Courtesy of FORD MOTOR CO.
17. Hold the case fitting and install the transmission cooler lines.
18. Install the four nuts.
    • Rotate the crankshaft as needed to gain access to all the nuts.
    Fig 15: Installing Nuts

    Courtesy of FORD MOTOR CO.

    2.3L Vehicles 

19. Install the four nuts.
    • Rotate the crankshaft as needed to gain access to all the nuts.
    Fig 16: Rotating Crankshaft As Needed To Gain Access To All Nuts

    Courtesy of FORD MOTOR CO.

    All Vehicles 

20. Install the starter motor. For additional information, refer to STARTERS .
21. Install the catalytic converter assembly.
22. Connect the transmission wiring harness.
    1. Connect the transmission connector.
    2. Connect the Intermediate Shaft Speed (ISS) sensor.
    3. Connect the digital Transmission Range (TR) sensor connector.
    4. Connect the Output Shaft Speed (OSS) sensor.
    Fig 17: Connecting Transmission Wiring Harness

    Courtesy of FORD MOTOR CO.
23. Install the shift cable.
    1. Connect the shift cable to manual control lever.
    2. Connect the shift cable to the bracket.
    Fig 18: Installing Shift Cable

    Courtesy of FORD MOTOR CO.
NOTE: Align the driveshaft yoke and the axle shaft marks made at removal to maintain driveline balance.
Fig 19: Installing Rear Driveshaft
Courtesy of FORD MOTOR CO.
24. Install the rear driveshaft.
    1. Position the driveshaft.
    2. Install the four bolts.
NOTE: If the vehicle was not equipped with a fluid filter, install a fluid filter kit. Follow the instructions supplied in the kit. If the vehicle was equipped with a filter, install a new filter.
Fig 20: Installing In-Line Transmission Fluid Filter
Courtesy of FORD MOTOR CO.
25. Install a new in-line transmission fluid filter kit or filter.
26. Lower the vehicle.

    4.0L SOHC Vehicles 

27. Install the transmission fill tube and indicator as an assembly.
    Fig 21: Installing Transmission Fill Tube & Indicator Assembly

    Courtesy of FORD MOTOR CO.

    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 may experience slightly different upshifts (either soft or firm) and this is a temporary condition that will eventually return to normal operating condition.
28. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
29. Fill the transmission with fluid and inspect for correct operation.
    • Use Motorcraft MERCON® V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford MERCON® V specification.
30. Verify that the shift cable is correctly adjusted. For additional information, refer to TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS .