Section 671 (Manual Transmission - F250-F550 Super Duty): Installation: Transmission

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Special Tool(s)

Fig 1: Identifying Special Tool

Courtesy of FORD MOTOR CO.

Material

ITEM SPECIFICATION CHART

Item	Specification
MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX	MERCON®
Gasket Maker F8AZ-19B508-AB	WSK-M2G348-A5
Threadlock and Sealer E0AZ-19554-AA	WSK-M2G351-A5 (type II)

All vehicles

Using the transmission jack, raise and position the transmission to the engine and clutch.
Install the transmission-to-engine bolts.
- For vehicles equipped with diesel engines, install six bolts.
- For vehicles equipped with gasoline engines, install seven bolts.
  
  Fig 2: Installing Transmission-To-Engine Bolts
  Courtesy of FORD MOTOR CO.
Install the LH crossmember bolts.

Fig 3: Installing LH Crossmember Bolts
Courtesy of FORD MOTOR CO.
Install the RH crossmember nuts.

Fig 4: Installing RH Crossmember Nuts
Courtesy of FORD MOTOR CO.
Install the transmission mount nuts.

Fig 5: Installing Transmission Mount Nuts
Courtesy of FORD MOTOR CO.
Install the engine plate bolts.

Fig 6: Installing Engine Plate Bolts (1 Of 2)
Courtesy of FORD MOTOR CO.

Fig 7: Installing Engine Plate Bolts (2 Of 2)
Courtesy of FORD MOTOR CO.
Remove the transmission jack.
Connect the transmission cooler tubes.

Fig 8: Connecting Transmission Cooler Tubes
Courtesy of FORD MOTOR CO.
Install the clutch slave cylinder.
- Rotate the clutch slave cylinder clockwise 45 degrees to lock in position.
  
  Fig 9: Installing Clutch Slave Cylinder
  Courtesy of FORD MOTOR CO.
Install the starter. Refer to STARTERS .
Install the transfer case, if equipped. Refer to TRANSFER CASE .
- If the transfer case control lever assembly was removed from the transmission, it must be correctly aligned.
Connect the driveshaft. Refer to DRIVESHAFT .
Install any power take-off (PTO) equipment, if equipped.
Connect the reverse lamp switch electrical connector.

Fig 10: Connecting Reverse Lamp Switch Electrical Connector
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Connect the wiring harness to the transmission.

Fig 11: Connecting Wiring Harness To Transmission
Courtesy of FORD MOTOR CO.
Refill the transmission to specification.
- Refill the transmission with clean transmission fluid.
Lower the vehicle.

CAUTION: Do not use a silicone sealing compound.

NOTE: Do not wait longer than ten minutes to tighten the six bolts due to the rapid cure time of the sealant.

Install the lower gearshift lever and shift housing assembly.
- Apply gasket maker to the shift housing and the main case.
  
  Fig 12: Applying Gasket Maker To Shift Housing And Main Case
  Courtesy of FORD MOTOR CO.
Install the lower shift lever boot.

Fig 13: Installing Lower Shift Lever Boot
Courtesy of FORD MOTOR CO.
Apply threadlock and sealer to the gearshift lever bolts. Install the upper gearshift lever.

Fig 14: Installing Upper Gearshift Lever
Courtesy of FORD MOTOR CO.
Install the screws.

Fig 15: Installing Screws
Courtesy of FORD MOTOR CO.

Vehicles with a manual shift lever
Position the shift lever with the bezel and boot assembly and install the bolt.

Fig 16: Installing Bolt
Courtesy of FORD MOTOR CO.
Position the bezel and boot assembly and install the screws.

Fig 17: Installing Screws
Courtesy of FORD MOTOR CO.
Verify the shift sequence from 2H to 4L to 2H.