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Transmission - E-150-450: Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

    ALL APPLICATIONS 

    CAUTION: Prior to the installation of the transmission the fluid coolers, cooler tubes and the cooler bypass valve will need to be cleaned. For additional information, refer to TRANSMISSION FLUID COOLER - BACKFLUSHING AND CLEANING .
  1. Inspect the wiring harness and the connectors for damage, terminal condition, corrosion and seal integrity. Repair or install new components as required.
    2. CAUTION: Prior to installation of the transmission assembly, the torque converter pilot hub must be lubricated.
    Fig 1: Lubricating Torque Converter Pilot Hub With Multi-Purpose Grease
    G01539386Courtesy of FORD MOTOR CO.
  2. Lubricate the torque converter pilot hub with multi-purpose grease.
    3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS sensor can occur.
    CAUTION: If a safety strap is being used to hold the transmission to the high lift transmission jack, place the strap behind the cooler bypass valve (CBV) to prevent damage to the cooler bypass valve.
    NOTE: Prior to installation, inspect the transmission wiring harness and the connectors for damage, terminal condition, corrosion and seal integrity. Repair or install new components as required.
    NOTE: Due to the proximity of the exhaust pipe, the bolt must be installed into the converter housing mounting hole above the starter motor mounting area prior to raising the transmission into the vehicle.
    Fig 2: Raising Transmission Into Vehicle
    G01539387Courtesy of FORD MOTOR CO.
  3. Position, then raise the transmission into the vehicle while watching for obstructions.
    4. CAUTION: Do not allow the torque converter drive flats to disengage from the pump gear. Use care not to damage the flexplate and the converter pilot. The torque converter must rest squarely against the flexplate, indicating the converter pilot is not binding in the crankshaft.
    Fig 3: Aligning Torque Converter Studs With Mounting Holes In Flexplate
    G01539388Courtesy of FORD MOTOR CO.
  4. While installing the transmission to the engine, align the torque converter studs with the mounting holes in the flexplate.
  5. Install and alternately snug the transmission-to-engine retaining bolts.
    Fig 4: Installing Snug Transmission-To-Engine Retaining Bolts
    G01539389Courtesy of FORD MOTOR CO.

    6. DIESEL ENGINES 

  6. Install the transmission-to-engine retaining bolts.
    Fig 5: Installing Transmission-To-Engine Retaining Bolts
    G01539390Courtesy of FORD MOTOR CO.
  7. Install the transmission-to-engine retaining bolts.
    Fig 6: Installing Transmission-To-Engine Retaining Bolts
    G01539391Courtesy of FORD MOTOR CO.

    8. ALL APPLICATIONS 

  8. Install torque converter-to-flexplate nuts.
    Fig 7: Installing Torque Converter-To-Flexplate Nuts
    G01539392Courtesy of FORD MOTOR CO.

    9. DIESEL ENGINES 

  9. Install new torque converter-to-flexplate nuts.
    Fig 8: Installing Torque Converter-To-Flexplate Nuts
    G01539393Courtesy of FORD MOTOR CO.

    10. ALL APPLICATIONS 

  10. Install the cylinder block opening cover.
    Fig 9: Installing Cylinder Block Opening Cover
    G01539394Courtesy of FORD MOTOR CO.
  11. Install the flexplate inspection cover and bolts.
    Fig 10: Installing Flexplate Inspection Cover And Bolts
    G01539395Courtesy of FORD MOTOR CO.

    12. DIESEL ENGINES 

  12. Install the flexplate inspection cover and bolts.
    Fig 11: Installing Flexplate Inspection Cover And Bolts
    G01539396Courtesy of FORD MOTOR CO.

    ALL APPLICATIONS 

    13. NOTE: If the transmission fluid cooler, cooler tubes, or cooler bypass valve have not been flushed it would be necessary to do so at this time.
    Fig 12: Connecting Fluid Cooler Tubes To CBV
    G01539397Courtesy of FORD MOTOR CO.
  13. Remove the plugs and connect the fluid cooler tubes to the CBV.

    14. DIESEL ENGINES 

    NOTE: If the transmission fluid cooler, cooler tubes, or cooler bypass valve have not been flushed it would be necessary to do so at this time.
    Fig 13: Connecting Fluid Cooler Tubes To CBV
    G01539398Courtesy of FORD MOTOR CO.
  14. With a suitable drain pan correctly positioned, remove the plugs and connect the fluid cooler tubes to the CBV.

    ALL APPLICATIONS 

    15. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS sensor could occur.
    Fig 14: Installing Transmission Support Crossmember
    G01539399Courtesy of FORD MOTOR CO.
  15. Install the transmission support crossmember.
  16. Install the rear transmission mount nuts.
    Fig 15: Installing Rear Transmission Mount Nuts
    G01539400Courtesy of FORD MOTOR CO.
  17. Remove the high lift transmission jack.
  18. Install the transmission fluid pan-to-case retaining bolts.
    Fig 16: Installing Transmission Fluid Pan-To-Case Retaining Bolts
    G01539401Courtesy of FORD MOTOR CO.
  19. Install the shift cable.
    Fig 17: Installing Shift Cable
    G01539402Courtesy of FORD MOTOR CO.

    DIESEL ENGINES 

  20. Connect the vehicle speed sensor (VSS) connector and the TSS sensor connector if equipped.
    Fig 18: Connecting Vehicle Speed Sensor Connector And TSS Sensor Connector
    G01539403Courtesy of FORD MOTOR CO.

    21. ALL APPLICATIONS 

  21. Connect the digital TR sensor connector.
    Fig 19: Connecting Digital TR Sensor Connector
    G01539404Courtesy of FORD MOTOR CO.
  22. Connect the solenoid body connector.
    Fig 20: Connecting Solenoid Body Connector
    G01539405Courtesy of FORD MOTOR CO.
  23. If equipped, install the exhaust heat shield and bolts.
    Fig 21: Installing Exhaust Heat Shield And Bolts
    G01539406Courtesy of FORD MOTOR CO.
  24. Install the starter motor. For additional information, refer to STARTERS - EXCEPT DIESEL , ENGINE-4.6L & 5.4L , ENGINE-6.8L or ENGINE-7.3L DIESEL .
  25. Install the driveshaft. For additional information, refer to DRIVESHAFT .
  26. 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 a non-internal repair, do not install an in-line filter or filter kit.
    • If installing 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.

    Fig 22: Installing In-Line Transmission Filter Or Filter Kit
    G01539407Courtesy of FORD MOTOR CO.
  27. Remove the supports and lower the vehicle.
  28. Install and alternately snug, then tighten the transmission-to-engine bolts.
    Fig 23: Tightening Transmission-To-Engine Bolts
    G01539408Courtesy of FORD MOTOR CO.
  29. Connect the electrical harness connectors.
    Fig 24: Connecting Electrical Harness Connectors
    G01539409Courtesy of FORD MOTOR CO.

    30. DIESEL ENGINES 

    NOTE: Prior to installation, check the condition of the transmission fluid filler tube O-ring. Install new if damaged.
    Fig 25: Installing Fluid Filler Tube Into Short Fluid Inlet Tube
    G01539410Courtesy of FORD MOTOR CO.
  30. Install the fluid filler tube into the short fluid inlet tube. Tighten the bolt.
  31. Position the retaining bracket for the fluid filler tube and install the nut.
    Fig 26: Positioning Retaining Bracket For Fluid Filler Tube
    G01539411Courtesy of FORD MOTOR CO.

    ALL APPLICATIONS 

    32. NOTE: Prior to installation, check the condition of the transmission fluid filler tube O-ring. Install new if damaged.
    Fig 27: Installing Fluid Filler Tube Into Short Fluid Inlet Tube
    G01539412Courtesy of FORD MOTOR CO.
  32. Install the fluid filler tube into the short fluid inlet tube. Tighten the nut.
  33. Position the retaining bracket for the fluid filler tube and install the nut.
    Fig 28: Positioning Retaining Bracket For Fluid Filler Tube
    G01539413Courtesy of FORD MOTOR CO.

    34. ALL GAS APPLICATIONS 

  34. Install the vapor management valve.
    Fig 29: Installing Vapor Management Valve
    G01539414Courtesy of FORD MOTOR CO.

    35. ALL APPLICATIONS 

  35. Install the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
    36. NOTE: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repairs, the strategy parameters that are stored in the keep alive memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the powertrain control module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If a concern is present during down shifts or converter clutch apply, it is not the shift strategy and will require diagnosis as outlined in the workshop manual.
  36. The customer needs to be notified that they may experience slightly different upshifts (either soft or firm) and that this condition is temporary and will eventually return to normal operating condition.

    Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .

  37. Install the transmission fluid level indicator.
    Fig 30: Installing Transmission Fluid Level Indicator
    G01539415Courtesy of FORD MOTOR CO.
  38. Install the air cleaner air intake duct assembly.
  39. Fill the transmission to the specified level using clean automatic transmission fluid.
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