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Transmission - F-Super Duty: Installation

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.

All applications 

CAUTION: Prior to the installation of a new or overhauled transmission, the fluid cooler lines must be cleaned. Otherwise transmission failure can occur.
    CAUTION: Prior to the installation of a new or overhauled transmission, a new transmission fluid cooler remote filter must be installed. Otherwise transmission failure can occur.
  1. If necessary, install a new transmission fluid cooler remote filter. Refer to TRANSAXLE/TRANSMISSION COOLING .
    2. 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 1: Lubricating Torque Converter Pilot Hub
    G02776102Courtesy of FORD MOTOR CO.
  2. Lubricate the torque converter pilot hub with multi-purpose grease.
  3. 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 2: Holding Torque Converter By Special Tool
    G02776103Courtesy of FORD MOTOR CO.
  4. 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 3: Aligning Fluid Filler Tube With Stub Tube
    G02776104Courtesy of FORD MOTOR CO.
  5. Install nine transmission-to-engine bolts.
    Fig 4: Installing Transmission-To-Engine Bolts
    G02776105Courtesy of FORD MOTOR CO.
  6. Using a suitable strap wrench to rotate the crankshaft and pulley, install the new torque converter-to-flexplate nuts.
    Fig 5: Installing Torque Converter-To-Flexplate Nuts
    G02776106Courtesy of FORD MOTOR CO.
  7. Install the cylinder block opening cover.
    Fig 6: Installing Cylinder Block Opening Cover
    G02776107Courtesy of FORD MOTOR CO.
  8. If equipped with dual generators, rotate the tensioner and install the outer accessory drive belt onto the crankshaft pulley.
    Fig 7: Installing Outer Accessory Drive Belt Onto Crankshaft Pulley
    G02776108Courtesy of FORD MOTOR CO.

    All applications 

  9. Install the front transmission fluid cooler tube.
    Fig 8: Installing Front Transmission Fluid Cooler Tube
    G02776109Courtesy of FORD MOTOR CO.
  10. Install the rear transmission fluid cooler tube.
    Fig 9: Installing Rear Transmission Fluid Cooler Tube
    G02776110Courtesy of FORD MOTOR CO.

    4x4 applications 

  11. Support the extension housing with a jack stand and remove the transmission jack.

    4x2 applications 

  12. Install the transmission mount.
    Fig 10: Installing Transmission Mount
    G02776111Courtesy of FORD MOTOR CO.
  13. Position the crossmember to the transmission mount and loosely install the nut.
    Fig 11: Positioning Crossmember To Transmission Mount
    G02776112Courtesy of FORD MOTOR CO.
  14. Install the LH crossmember bolts.
    Fig 12: Installing LH Crossmember Bolts
    G02776113Courtesy of FORD MOTOR CO.
  15. Install the RH crossmember bolts.
    Fig 13: Installing RH Crossmember Bolts
    G02776114Courtesy of FORD MOTOR CO.
  16. Install the bracket and loosely install the bolts.
    1. Install the bracket.
    2. Loosely install the bolts.
      Fig 14: Install Bracket And Bolts
      G02776115Courtesy of FORD MOTOR CO.
  17. Tighten the RH crossmember bolts.
    Fig 15: Tightening RH Crossmember Bolts
    G02776116Courtesy of FORD MOTOR CO.
  18. Tighten the rear insulator nuts.
    Fig 16: Tightening Rear Insulator Nuts
    G02776117Courtesy of FORD MOTOR CO.

    All applications 

    19. NOTE: RH shown, LH similar.
    Fig 17: Connecting RH And LH Wiring Harness To Side Of Transmission
    G02776118Courtesy of FORD MOTOR CO.
  19. Connect the RH and LH wiring harness to the side of the transmission.
  20. Connect the output shaft speed (OSS) sensor electrical connector.
    Fig 18: Connecting Output Shaft Speed Sensor Electrical Connector
    G02776119Courtesy of FORD MOTOR CO.
  21. Connect the intermediate shaft and turbine shaft combination speed sensor electrical connector.
    Fig 19: Connecting Intermediate Shaft Speed Sensor Electrical Connector
    G02776120Courtesy of FORD MOTOR CO.
  22. Connect the solenoid body electrical connector.
    Fig 20: Connecting Solenoid Body Electrical Connector
    G02776121Courtesy of FORD MOTOR CO.
    23. NOTE: If the vehicle is equipped with a power take-off unit, all or part of the PTO unit will need to be installed.
  23. Connect the shift cable.
    1. Install the cable housing bracket.
    2. Install the shift cable to the manual lever.
      Fig 21: Illustration Steps-1 And 2
      G02776122Courtesy of FORD MOTOR CO.

    4x2 applications 

  24. Reconnect the wire harness to the frame.
    Fig 22: Connecting Wire Harness To Frame
    G02776123Courtesy of FORD MOTOR CO.

    4x4 applications 

  25. If equipped, install the transfer case. Refer to TRANSFER CASE .

    4x2 applications 

  26. Install the rear driveshaft. Refer to DRIVESHAFT .

    All applications 

    27. NOTE: Use the following guidelines for the in-line transmission 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 the in-line fluid filter, install a new in-line fluid filter.
    • 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.
  27. Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit. Refer to TRANSMISSION FLUID IN-LINE FILTER .
  28. Connect the battery ground cable. Refer to BATTERY, MOUNTING AND CABLES .
  29. Adjust the shift linkage. Verify that the vehicle starts in PARK and NEUTRAL and the REVERSE lamps illuminate in REVERSE. Refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS .
  30. For vehicles equipped with a PTO assembly, prior to installing the transmission, the PTO assembly must be flushed and cleaned to remove any foreign material. Failure to remove foreign material from the PTO assembly may result in subsequent transmission concerns.
  31. 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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