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Transmission - Diesel Engines

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS SPECIFICATIONS

G04000543
 High Lift Transmission Jack 014-00942
MATERIAL SPECIFICATIONS

Item Specification
MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX MERCON®
Gasket Maker F8AZ-19B508-AB WSK-M2G348-A5

    All vehicles 

  1. Using the transmission jack, raise and position the transmission to the engine and clutch.
  2. Install the six transmission-to-engine bolts.
    Fig 1: Identifying Tightening Torque Of Transmission-To-Engine Bolts
    G03923685Courtesy of FORD MOTOR CO.
  3. Position the crossmember in the vehicle. Install the LH crossmember bolts.
    Fig 2: Identifying Tightening Torque Of LH Crossmember Bolts
    G03923686Courtesy of FORD MOTOR CO.
  4. Install the RH crossmember nuts.
    Fig 3: Identifying Tightening Torque Of RH Crossmember Nuts
    G03923687Courtesy of FORD MOTOR CO.
  5. Install the transmission mount nuts.
    Fig 4: Identifying Tightening Torque Of Transmission Mount Nuts
    G03923688Courtesy of FORD MOTOR CO.
  6. Attach the wire harness to the crossmember.
  7. Remove the transmission jack.
  8. Connect the transmission cooler tubes.
    Fig 5: Identifying Tightening Torque Of Transmission Cooler Tubes
    G03923689Courtesy of FORD MOTOR CO.
  9. Install the clutch slave cylinder.
    • Rotate the clutch slave cylinder clockwise 45 degrees to lock in position.
      Fig 6: Installing Clutch Slave Cylinder
      G03923690Courtesy of FORD MOTOR CO.
  10. Install the transfer case, if equipped. For additional information, refer to TRANSFER CASE .
    • If the transfer case control lever assembly was removed from the transmission, it must be correctly aligned.
    11. NOTE: Make sure the index marks made during removal are aligned.
    NOTE: Install new bolts.
    Fig 7: Identifying Tightening Torque Of Driveshaft Bolts
    G03909841Courtesy of FORD MOTOR CO.
  11. Connect the driveshaft.
  12. Install any power take-off (PTO) equipment, if equipped.
    Fig 8: Installing Power Take-Off (PTO) Equipment
    G03923403Courtesy of FORD MOTOR CO.
  13. Connect the reverse lamp switch electrical connector.
    Fig 9: Connecting Reverse Lamp Switch Electrical Connector
    G03923425Courtesy of FORD MOTOR CO.
  14. Connect the wiring harness to the transmission.
  15. Refill the transmission to specification.
    • Refill the transmission with clean transmission fluid.
  16. Lower the vehicle.
    17. CAUTION: Do not use a silicone sealing compound.
    NOTE: Do not wait longer then ten minutes to tighten the four bolts due to the rapid cure time of the sealant.
  17. Install the gearshift lever and shift housing assembly.
    • Apply gasket maker to the shift housing and the main case.
      Fig 10: Identifying Tightening Torque Of Shift Housing Assembly Bolts
      G03923694Courtesy of FORD MOTOR CO.
  18. Install the four shift lever boot screws.
    Fig 11: Identifying Gear Shift Lever Boot Screws
    G03923381Courtesy of FORD MOTOR CO.

    19. Vehicles with a manual shift transfer case 

  19. Position the shift lever with the bezel and boot assembly. Install the shift lever bolt.
  20. Position the bezel and boot assembly and install the screws.
    Fig 12: Identifying Bezel And Boot Assembly Screws
    G03909667Courtesy of FORD MOTOR CO.
  21. Verify the shift sequence from 2H to 4L to 2H.
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