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Transmission - Diesel Engines: Installation

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Install a new oil-to-air (OTA) cooler as part of a transmission overhaul, or when installing a remanufactured transmission due to major metallic failure, multiple clutches or clutch plate failures or sufficient component wear, which results in metallic contamination.
NOTE: Prior to installation of a new or overhauled transmission, the transmission fluid cooler lines must be cleaned.
    NOTE: 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.
  1. Lubricate the torque converter pilot hub with multi-purpose grease.
    2. Fig 1: Identifying Torque Converter Pilot Hub
    G03889591Courtesy of FORD MOTOR CO.
  2. Rotate the torque converter so the orange or green paint daub is in the 12 o'clock position.
  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.
    4. Fig 2: Identifying Special Tool (307-346) On Transmission Assembly
    G04616002Courtesy of FORD MOTOR CO.
  4. Install a new transmission fluid filler tube O-ring.
    5. Fig 3: Locating O-Ring Seal
    G03889046Courtesy of FORD MOTOR CO.
  5. Position the transmission in place. While raising the transmission up into the engine compartment, align the transmission fluid filler tube with the stub tube on the transmission using the transmission 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.

    6. Fig 4: Aligning Fluid Filler Tube With Stub Tube On Transmission
    G03889593Courtesy of FORD MOTOR CO.
  6. Position the bracket in place and install the 9 transmission-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    7. Fig 5: Locating Transmission-To-Engine Mounting Bolts (Left Side)
    G03889230Courtesy of FORD MOTOR CO.
  7. Using the special tool, rotate the crankshaft to gain access to the torque converter studs.
    8. Fig 6: Special Tool (303-D055)
    GF0012425Courtesy of FORD MOTOR CO.
  8. Install the new torque converter-to-flexplate nuts.
    • Tighten to 48 Nm (35 lb-ft).
    9. Fig 7: Locating Torque Converter-To-Flexplate Nuts
    GF0002674Courtesy of FORD MOTOR CO.
  9. Install the cylinder block opening cover.
    10. Fig 8: Identifying Cylinder Block Torque Converter Access Cover
    G03889219Courtesy of FORD MOTOR CO.
  10. Install the insulator and bolts.
    • Tighten to 94 Nm (69 lb-ft).
    11. Fig 9: Locating Rear Transmission Mount Bolts At Extension Housing
    G03889228Courtesy of FORD MOTOR CO.
  11. Position the crossmember to the insulator and loosely install the nut.
    12. Fig 10: Locating Crossmember To Transmission Mount Nut
    G03889185Courtesy of FORD MOTOR CO.
  12. Install the LH crossmember bracket.
    13. Fig 11: Locating LH Crossmember Bracket
    G03889062Courtesy of FORD MOTOR CO.
  13. Install the LH crossmember nuts.
    • Tighten to 81 Nm (60 lb-ft).
    14. Fig 12: Identifying LH Crossmember Nuts
    G03889061Courtesy of FORD MOTOR CO.
  14. Install the RH crossmember bracket.
    15. Fig 13: Identifying RH Crossmember Bracket
    G03889064Courtesy of FORD MOTOR CO.
  15. Install the RH crossmember nuts.
    • Tighten to 81 Nm (60 lb-ft).
    16. Fig 14: Identifying RH Crossmember Nuts
    G03889063Courtesy of FORD MOTOR CO.
  16. Tighten the insulator nuts to 94 Nm (69 lb-ft).
    17. Fig 15: Identifying Transmission Support Insulator Nuts
    G03889099Courtesy of FORD MOTOR CO.
  17. Connect the transmission fluid cooler tubes onto the bracket.
    18. Fig 16: Transmission Fluid Cooler Tube Rear Bracket
    GF0012474Courtesy of FORD MOTOR CO.
  18. Install the transmission fluid cooler tube inlet fitting.
    • Tighten to 40 Nm (30 lb-ft).
    19. Fig 17: Rear Fluid Cooler Tube Fitting
    GF0006850Courtesy of FORD MOTOR CO.
  19. Install the transmission fluid cooler tube outlet fitting.
    • Tighten to 40 Nm (30 lb-ft).
    20. Fig 18: Front Fluid Cooler Tube Fitting
    GF0006851Courtesy of FORD MOTOR CO.
  20. Connect the wire harness to the bracket.
    21. Fig 19: Locating Wire Harness And Bracket
    G03889229Courtesy of FORD MOTOR CO.
  21. Install the wire harness retaining clip into the transmission on the LH side.
    22. Fig 20: Locating RH And LH Wire Harness From Side Of Transmission
    GF0006846Courtesy of FORD MOTOR CO.
  22. Connect the wire harness on the RH side of the transmission.
    23. Fig 21: Locating Wire Harness On RH Side Of Transmission
    G03889215Courtesy of FORD MOTOR CO.
  23. Connect the output shaft speed (OSS) sensor electrical connector.
    24. Fig 22: Identifying Output Shaft Speed (OSS) Sensor Electrical Connector
    G03889074Courtesy of FORD MOTOR CO.
  24. Connect the turbine shaft speed (TSS) and intermediate shaft speed combination sensor electrical connector.
    25. Fig 23: Identifying Intermediate Shaft And Turbine Shaft Combination Speed Sensor Electrical Connector
    G03889065Courtesy of FORD MOTOR CO.
  25. Connect the vehicle wire harness electrical connector.
    • Tighten to 5 Nm (44 lb-in).
    26. Fig 24: Identifying Solenoid Body Electrical Connector
    G03889052Courtesy of FORD MOTOR CO.
  26. Install the selector lever cable and bracket onto the transmission.
    1. Position the selector lever cable bracket and install the bolts.
      • Tighten to 48 Nm (35 lb-ft).
    2. Connect the selector lever cable onto the manual lever.
    3. Connect the wire harness onto the selector lever cable bracket.
    27. Fig 25: Locating Selector Lever Cable, Wire Harness & Bolts
    GF0044792Courtesy of FORD MOTOR CO.
  27. If equipped, install the selector lever cable onto the routing clip.
    28. Fig 26: Locating Selector Lever Cable From Routing Clip
    GF0044772Courtesy of FORD MOTOR CO.
  28. If equipped, install the wire harness and install the 2 retaining clips to the rear of the crossmember.
    29. Fig 27: Identifying Wire Harness Retaining Clips
    G03889060Courtesy of FORD MOTOR CO.
  29. Install the rear driveshaft. For additional information, refer to DRIVESHAFT article.
  30. Use the following guidelines for the transmission fluid inline filter:
    • If the transmission was overhauled and the vehicle was equipped with a transmission fluid inline filter, install a new transmission inline filter.
    • If the transmission was overhauled and the vehicle was not equipped with a transmission fluid inline filter, install a new transmission inline filter kit.
    • If the transmission is being installed for a non-internal repair, do not install a transmission fluid inline filter or filter kit.
    • If installing a new or a Ford authorized remanufactured transmission, install a transmission fluid inline filter.

      Prior to lowering the vehicle, install a new transmission fluid inline filter or a filter kit.

  31. Adjust the selector lever linkage. Verify that the vehicle starts in PARK and NEUTRAL and the reverse lamps illuminate in REVERSE. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS article.
  32. Install the transmission fluid level indicator.
  33. 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 transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved (transmission fluid should be in the hot range cross-hatched area of the transmission fluid level indicator).
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