Section 912 (Automatic Transmission - 4R100 - Excursion & F250-F550 Super Duty): Removal: Transmission: Removal

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.

All vehicles

With the vehicle in NEUTRAL position it on a hoist. Refer to Jacking & Lifting .

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts (either soft or firm) and that this is a temporary condition that will eventually return to normal operating condition.

Disconnect the battery ground cable. Refer to BATTERY, MOUNTING AND CABLES .
4x4 vehicles
Remove the transfer case assembly. Refer to TRANSFER CASE .
4x2 vehicles
Remove the rear driveshaft. Refer to DRIVESHAFT .
All vehicles
If transmission disassembly is required, drain the transmission fluid.
Vehicles equipped with a fluid pan drain plug
Remove the drain plug and allow the fluid to drain.

Fig 1: Removing Drain Plug And Allow Fluid-Drain
Courtesy of FORD MOTOR CO.
Install the drain plug.

Fig 2: Installing Drain Plug
Courtesy of FORD MOTOR CO.

Vehicles not equipped with a fluid pan drain plug

NOTE: Do not discard the gasket unless damaged. This is a reusable gasket.
Remove the transmission fluid pan and gasket.

Fig 3: Removing Transmission Fluid Pan And Gasket
Courtesy of FORD MOTOR CO.

NOTE: The transmission pan gasket is reusable unless damaged.

NOTE: Apply a light coat of petroleum jelly to hold the gasket to the fluid pan.
Position the gasket onto the cleaned fluid pan. Make sure the magnet is positioned over the dimple in the fluid pan.

Fig 4: Positioning Gasket Onto Cleaned Fluid Pan
Courtesy of FORD MOTOR CO.

CAUTION: Mixing the 4x2 and the 4x4 style transmission fluid filters and transmission pan assembly components can cause transmission damage.
Install the correct pan with gasket for this application. Alternately tighten the bolts.

Fig 5: Installing Correct Pan With Gasket For Application
Courtesy of FORD MOTOR CO.

CAUTION: Make sure securing straps or the transmission jack adapter do not touch the cooler bypass valve (CBV). Do not use the CBV as a handle. Damage to the CBV can cause a leak.
Install a suitable transmission jack and support the transmission.
4x4 vehicles
Remove the jack stand after installing a suitable transmission jack.
4x2 Excursion
Disconnect the wire loom from the crossmember.

Fig 6: Disconnecting Wire Loom From Crossmember
Courtesy of FORD MOTOR CO.
Remove the crossmember bolts.

Fig 7: Removing Crossmember Bolts
Courtesy of FORD MOTOR CO.
Remove the crossmember bolts.

Fig 8: Removing Crossmember
Courtesy of FORD MOTOR CO.
Remove the transmission mount nuts and the crossmember.

Fig 9: Removing Transmission Mount Nuts And Crossmember
Courtesy of FORD MOTOR CO.

F-Super Duty and 4x2 vehicles
Remove the RH crossmember nuts.

Fig 10: Removing Rh Crossmember Nuts
Courtesy of FORD MOTOR CO.
Remove the LH crossmember nuts.

Fig 11: Removing LH Crossmember Nuts
Courtesy of FORD MOTOR CO.
Remove the nuts and the crossmember.

Fig 12: Removing Nuts And Crossmember
Courtesy of FORD MOTOR CO.

All 4x2 vehicles
Remove the transmission mount.

Fig 13: Removing Transmission Mount
Courtesy of FORD MOTOR CO.

Vehicles equipped with a transmission-mounted parking brake
Disconnect and lubricate.
1. Disconnect the parking brake lever return spring from the parking brake lever.
2. Apply penetrating oil to the adjusting clevis, jam nut and the threads on the front parking brake cable and conduit.
  
  Fig 14: Applying Penetrating Oil-Adjusting Clevis Jam Nut
  Courtesy of FORD MOTOR CO.
Disconnect the front parking brake cable and conduit.
1. Loosen the jam nut.
2. Remove the clevis locking pin.
3. Remove the clevis pin.
4. Remove the adjusting clevis from the parking brake lever.
  
  Fig 15: Disconnecting Front Parking Brake Cable And Conduit
  Courtesy of FORD MOTOR CO.
Compress the retainer, and remove the front parking brake cable and conduit from the cable bracket.

Fig 16: Removing Front Parking Brake Cable And Conduit From Cable Bracket
Courtesy of FORD MOTOR CO.

All vehicles

NOTE: If the vehicle is equipped with a power take-off unit, all or part of the PTO unit will need to be removed.
Disconnect the shift cable from the transmission.
1. Disconnect the shift cable from the manual lever.
2. Remove the shift cable bracket from the transmission and position aside.
  
  Fig 17: Removing Shift Cable Bracket From Transmission And Position
  Courtesy of FORD MOTOR CO.
Disconnect the digital transmission range (TR) sensor connector and the wire loom from the shift cable bracket.

Fig 18: Disconnecting Digital Transmission Range (TR) Sensor Connector
Courtesy of FORD MOTOR CO.
Disconnect the solenoid body connector.

Fig 19: Disconnecting Solenoid Body Connector
Courtesy of FORD MOTOR CO.
Disconnect the turbine shaft speed (TSS) sensor and the output shaft speed (OSS) sensor.

Fig 20: Disconnecting Turbine Shaft Speed (TSS) Sensor And Output Shaft Speed (OSS) Sensor
Courtesy of FORD MOTOR CO.
Remove the wiring harness from the transmission and position aside.
Remove the flexplate inspection cover.
1. Remove the bolts.
2. Remove the inspection plate.
  
  Fig 21: Removing Wiring Harness From Transmission And Position
  Courtesy of FORD MOTOR CO.
Remove the starter motor. Refer to STARTERS .
Remove the cylinder block opening cover.

Fig 22: Removing Cylinder Block Opening Cover
Courtesy of FORD MOTOR CO.
Remove and discard the torque converter-to-flexplate nuts.
- 5.4L engine has four torque converter-to-flexplate nuts.
- 6.8L engine has six torque converter-to-flexplate nuts.
  
  Fig 23: Removing And Discard Torque Converter-To-Flexplate Nuts
  Courtesy of FORD MOTOR CO.
Position a suitable drain pan and disconnect the transmission fluid cooler tubes from the cooler bypass valve.

Fig 24: Disconnecting Transmission Fluid Cooler Tubes From Cooler Bypass Valve
Courtesy of FORD MOTOR CO.
Remove the transmission.
1. Remove the seven transmission-to-engine mounting bolts.
2. Gently rock the transmission side-to-side to disengage it from the locator dowels.
3. Move the transmission and the transmission jack rearward to clear the engine flexplate.
Fig 25: Removing Seven Transmission-To-Engine Mounting Bolts
Courtesy of FORD MOTOR CO.

WARNING: The torque converter is heavy and can result in injury if it falls out of the transmission. Secure the torque converter in the transmission. If the torque converter is dropped, a new one must be installed.

Fig 26: Holding Torque Converter In Place

Courtesy of FORD MOTOR CO.

Using the special tool, hold the torque converter in place.

CAUTION: Use care while removing the transmission to avoid obstructions.

CAUTION: Do not use the cooler bypass valve as a handle. Damage to the cooler bypass valve assembly can occur or damage to the case can result.

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.

Fig 27: Removing Transmission-Avoid Obstructions

Courtesy of FORD MOTOR CO.

Lower the transmission out of the vehicle.
Vehicles equipped with a transmission-mounted parking brake
Remove the transmission-mounted parking brake.
1. Keep the parking brake vent in the upward position to prevent contamination of the brake shoes and linings.
2. Remove the six bolts, parking brake assembly and the gasket from the extension housing.
  - Discard the bolts and the gasket. Clean the mating surfaces.
    
    Fig 28: Removing Transmission-Mounted Parking Brake
    Courtesy of FORD MOTOR CO.
All vehicles
If the transmission is being overhauled or if installing a new or remanufactured transmission, carry out the TRANSMISSION FLUID COOLER - BACKFLUSHING AND CLEANING .