Transmission - Excursion: 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.

CAUTION: Prior to the installation of the transmission, the fluid cooler lines must be cleaned. Otherwise transmission failure can occur.

Clean the fluid cooler lines. Refer to TRANSMISSION FLUID COOLER - BACKFLUSHING AND CLEANING .

CAUTION: Prior to the installation of the transmission, a new transmission fluid cooler remote filter must be installed. Otherwise transmission failure can occur.

Install a new transmission fluid cooler remote filter. Refer to TRANSAXLE/TRANSMISSION COOLING .

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

Courtesy of FORD MOTOR CO.

Lubricate the torque converter pilot hub with multi-purpose grease.
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 and before bolting it to the engine remove the special tool.

Fig 2: Holding Torque Converter By Special Tool
Courtesy of FORD MOTOR CO.
Position the transmission in place. While raising the transmission 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
Courtesy of FORD MOTOR CO.
Install nine transmission-to-engine bolts.

Fig 4: Installing Transmission-To-Engine Bolts
Courtesy of FORD MOTOR CO.

NOTE: Using a suitable strap wrench, rotate the crankshaft pulley to gain access to the torque converter nuts.

Fig 5: Installing Torque Converter-To-Flexplate Nuts

Courtesy of FORD MOTOR CO.

Install six new torque converter-to-flexplate nuts.
Install the cylinder block opening cover.

Fig 6: Installing Cylinder Block Opening Cover
Courtesy of FORD MOTOR CO.
Install the front transmission fluid cooler tube.

Fig 7: Installing Front Transmission Fluid Cooler Tube
Courtesy of FORD MOTOR CO.
Install the rear transmission fluid cooler tube.

Fig 8: Installing Rear Transmission Fluid Cooler Tube
Courtesy of FORD MOTOR CO.

4x4 applications
Support the extension housing with a jack stand and remove the transmission jack.
4x2 applications
Install the transmission mount.

Fig 9: Installing Transmission Mount
Courtesy of FORD MOTOR CO.
Position the crossmember to the transmission mount and loosely install the nut.

Fig 10: Positioning Crossmember To Transmission Mount
Courtesy of FORD MOTOR CO.
Install the LH crossmember bolts.

Fig 11: Installing LH Crossmember Bolts
Courtesy of FORD MOTOR CO.
Install the RH crossmember bolts.

Fig 12: Installing RH Crossmember Bolts
Courtesy of FORD MOTOR CO.
Tighten the rear insulator nuts.

Fig 13: Tightening Rear Insulator Nuts
Courtesy of FORD MOTOR CO.

NOTE: RH shown.

Fig 14: Connecting RH And LH Wiring Harness To Side Of Transmission

Courtesy of FORD MOTOR CO.

Connect the RH and LH wiring harness to the side of the transmission.
Connect the output shaft speed (OSS) sensor electrical connector.

Fig 15: Connecting Output Shaft Speed Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the intermediate shaft and turbine shaft combination speed sensor electrical connector.

Fig 16: Connecting Intermediate Shaft Speed Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the solenoid body electrical connector.

Fig 17: Connecting Solenoid Body Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the shift cable.
1. Install the cable housing bracket.
2. Install the shift cable to the manual lever.
  
  Fig 18: Illustration Steps-1 And 2
  Courtesy of FORD MOTOR CO.
4x2 applications
Reconnect the wire harness to the frame.

Fig 19: Connecting Wire Harness To Frame
Courtesy of FORD MOTOR CO.

4x4 applications
If equipped, install the transfer case. Refer to TRANSFER CASE .
4x2 applications
Install the rear driveshaft. Refer to DRIVESHAFT .
All applications
Connect the battery ground cable. Refer to BATTERY, MOUNTING AND CABLES .
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 .
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).
Use the following guidelines for the in-line transmission fluid 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 an in-line fluid filter, install a new in-line fluid filter kit.
- If the transmission is being installed for 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.
  Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit. Refer to TRANSMISSION FLUID IN-LINE FILTER .