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Transmission - Gasoline 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 seven transmission-to-engine bolts.
    Fig 1: Identifying Tightening Torque Of Transmission-To-Engine Bolts
    G03923698Courtesy 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
    G03923699Courtesy of FORD MOTOR CO.
  4. Install the RH crossmember nuts.
    Fig 3: Identifying Tightening Torque Of RH Crossmember Nuts
    G03923700Courtesy of FORD MOTOR CO.
  5. Install the transmission mount nuts.
    Fig 4: Identifying Tightening Torque Of Transmission Mount Nuts
    G03923701Courtesy of FORD MOTOR CO.
  6. Attach the wire harness to the crossmember.
  7. Install the dust cover bolts.
    Fig 5: Identifying Tightening Torque Of Dust Cover Bolts (1 Of 2)
    G03923702Courtesy of FORD MOTOR CO.
    Fig 6: Identifying Tightening Torque Of Dust Cover Bolts (2 Of 2)
    G03923703Courtesy of FORD MOTOR CO.
  8. Remove the transmission jack.
  9. Connect the transmission cooler tubes.
    Fig 7: Identifying Tightening Torque Of Transmission Cooler Tubes
    G03923704Courtesy of FORD MOTOR CO.
  10. Install the clutch slave cylinder.
    • Rotate the clutch slave cylinder clockwise 45 degrees to lock in position.
      Fig 8: Installing Clutch Slave Cylinder
      G03923690Courtesy of FORD MOTOR CO.
  11. Install the starter. For additional information, refer to STARTING SYSTEM - DIESEL ENGINE .
  12. Install the exhaust Y-pipe. For additional information, refer to EXHAUST SYSTEM .
  13. 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.
  14. Connect the driveshaft.
  15. Install any power take-off (PTO) equipment, if equipped.
  16. Connect the fuel lines to the transmission.
    Fig 9: Connecting Fuel Lines To Transmission
    G03923403Courtesy of FORD MOTOR CO.
  17. Connect the reverse lamp switch electrical connector.
    Fig 10: Connecting Reverse Lamp Switch Electrical Connector
    G03923408Courtesy of FORD MOTOR CO.
  18. Connect the wiring harness to the transmission.
    Fig 11: Connecting Wiring Harness To Transmission
    G03923409Courtesy of FORD MOTOR CO.
  19. Refill the transmission to specification.
    • Refill the transmission with clean transmission fluid.
  20. Lower the vehicle.
    21. 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.
  21. Install the gearshaft lever and shift housing assembly.
    • Apply gasket maker to the shift housing and the main case.
      Fig 12: Identifying Tightening Torque Of Gearshaft Lever And Shift Housing Assembly Bolts
      G03923709Courtesy of FORD MOTOR CO.
  22. Install the lower shift lever boot.
    Fig 13: Installing Lower Shift Lever Boot
    G03923383Courtesy of FORD MOTOR CO.
  23. Apply threadlock and sealer to the gearshift lever bolts. Install the upper gearshift lever.
    Fig 14: Identifying Tightening Torque Of Upper Gearshift Lever Bolts
    G03923392Courtesy of FORD MOTOR CO.
  24. Install the screws.
    Fig 15: Identifying Gear Shift Lever Boot Screws
    G03923381Courtesy of FORD MOTOR CO.

    25. Vehicles with a manual shift transfer case 

  25. Position the shift lever with the bezel and boot assembly and install the bolt.
    Fig 16: Identifying Tightening Torque Of Bezel And Boot Assembly Bolt
    G03909666Courtesy of FORD MOTOR CO.
  26. Position the bezel and boot assembly and install the screws.
    Fig 17: Identifying Bezel And Boot Assembly Screws
    G03909667Courtesy of FORD MOTOR CO.
  27. Verify the shift sequence from 2H to 4L to 2H.
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