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Installation (F250-F550)

WARNING: This page is about a different car, the 2002 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using the transmission jack, raise and position the transmission to the engine and clutch. Install the transmission-to-engine bolts.
  2. On models equipped with diesel engines, install 6 bolts. On models equipped with gasoline engines, install 7 bolts. On all models, tighten transmission-to-engine bolts to specification. See TORQUE SPECIFICATIONS  .
  3. Install the left and right side crossmember bolts and nuts. See Figure . Tighten left and right side crossmember bolts and nuts to specification. See TORQUE SPECIFICATIONS  .
  4. Install the transmission mount nuts. See Figure . Install the dust cover bolts. See Figure . Remove the transmission jack.
  5. Connect the transmission cooler tubes. See Figure . Install the clutch slave cylinder by rotating the it clockwise 45 degrees to lock in position. Install the starter. See appropriate STARTERS article.
  6. On models equipped with 4WD, install the transfer case. See appropriate REMOVAL & INSTALLATION article. If the transfer case control lever assembly was removed from the transmission, it must be correctly aligned. Install the front drive shaft. See DRIVE SHAFTS - EXCURSION & F250-F550 article in DRIVE AXLES.
  7. On all models, install rear drive shaft. Align reference marks made during removal. See DRIVE SHAFTS - EXCURSION & F250-F550 article in DRIVE AXLES. Tighten rear drive shaft bolts to specification. See TORQUE SPECIFICATIONS  .
  8. Install any PTO equipment that was removed, if equipped. Connect the reverse light switch harness connector. See Figure . Connect the wiring harness to the transmission. Fill the transmission to proper level with appropriate fluid. See SERVICING - M/T article in MANUAL TRANSMISSIONS.
    9. NOTE: DO NOT use a silicone sealing compound. DO NOT wait longer than 10 minutes to tighten the 6 bolts due to the rapid cure time of the sealant.
  9. Lower the vehicle. Install the lower gearshift lever and shift housing assembly. See Figure . Apply gasket maker to the shift housing and the main case.
  10. Install the lower shift lever boot. Apply threadlock and sealer to the gearshift lever bolts. See Figure . Install the upper gearshift lever and install the screws. See Figure .
  11. On models equipped with 4WD, position the transfer case shift lever with the bezel and boot assembly. Install the transfer case shift lever bolt and tighten to specification. See Figure . See TORQUE SPECIFICATIONS  . Position the bezel and boot assembly and install the screws. Verify the shift sequence from 2H to 4L to 2H.
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