Transmission - Diesel Engines: Removal

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Remove the fluid level indicator.
Remove the driveshaft. For additional information, refer to DRIVESHAFT .
If transmission disassembly is required, drain the transmission fluid. Remove the drain plug and allow the fluid to drain

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

Fig 2: Installing Drain Plug
Courtesy of FORD MOTOR CO.
Install a suitable high-lift transmission jack.
If equipped, remove the two wire harness retainers from the rear crossmember and position the wire harness out of the way.

Fig 3: Removing Wire Harness Retainers From Rear Crossmember
Courtesy of FORD MOTOR CO.
If equipped, disconnect the transmission-mounted parking brake linkage.
1. Disconnect the return spring from the pin.
2. Remove the hair pin retaining clip from the pin.
3. Remove the pin from the actuating lever and move the actuating cable away from the actuating lever.
4. Compress the spring on the actuating cable and remove the cable from the cable housing.
  
  Fig 4: Removing Cable From Cable Housing
  Courtesy of FORD MOTOR CO.
Disconnect the transmission fluid cooler tubes from the clips.

Fig 5: Disconnecting Transmission Fluid Cooler Tubes From Clips
Courtesy of FORD MOTOR CO.
Remove the retainers from the transmission fluid cooler tubes at the remote filter.

Fig 6: Removing Retainers From Transmission Fluid Cooler Tubes
Courtesy of FORD MOTOR CO.
Use the special tool to disconnect the transmission cooler tubes.

Fig 7: Disconnecting Transmission Cooler Tubes Using Special Tool
Courtesy of FORD MOTOR CO.
Remove the shift cable.
1. Remove the transmission fluid filter bracket nut.
2. Remove the transmission fluid filter bracket bolt, position the bracket aside.
3. Disconnect the shift cable from the manual lever.
4. Disconnect the wire harness from the shift cable bracket.
5. Remove the bolts and position the shift cable and bracket aside.
  
  Fig 8: Removing Bolts And Positioning Shift Cable And Bracket Aside
  Courtesy of FORD MOTOR CO.
Disconnect the oil cooler tubes from the filter housing.

Fig 9: Disconnecting Oil Cooler Tubes From Filter Housing
Courtesy of FORD MOTOR CO.
Remove the bolts and remove the filter housing.

Fig 10: Removing Bolts And Filter Housing
Courtesy of FORD MOTOR CO.
Loosen the bolt and disconnect the solenoid body electrical connector.

Fig 11: Disconnecting Solenoid Body Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect and position the wire harness out of the way.

Fig 12: Disconnecting And Positioning Wire Harness
Courtesy of FORD MOTOR CO.
Disconnect the output shaft speed (OSS) sensor electrical connector.

Fig 13: Disconnecting Output Shaft Speed (OSS) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the turbine shaft and intermediate shaft combination speed sensor electrical connector.

Fig 14: Disconnecting Turbine Shaft And Intermediate Shaft Combination Speed Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the wire harness from the side of the transmission.

Fig 15: Disconnecting Wire Harness From Side Of Transmission
Courtesy of FORD MOTOR CO.
Remove the cylinder block opening cover in order to gain access to the torque converter nuts.

Fig 16: Removing Cylinder Block Opening Cover In Order To Gain Access To Torque Converter Nuts
Courtesy of FORD MOTOR CO.
Use the special tool to rotate the crankshaft in order to gain access to the flexplate nuts.

Fig 17: Rotating Crankshaft In Order To Gain Access To Flexplate Nuts
Courtesy of FORD MOTOR CO.
Remove and discard the six torque nuts.

Fig 18: Removing Six Torque Nuts
Courtesy of FORD MOTOR CO.
Remove the LH crossmember nuts.

Fig 19: Removing LH Crossmember Nuts
Courtesy of FORD MOTOR CO.
Remove the LH crossmember bracket.

Fig 20: Removing LH Crossmember Bracket
Courtesy of FORD MOTOR CO.
Remove the RH crossmember nuts.

Fig 21: Removing RH Crossmember Nuts
Courtesy of FORD MOTOR CO.
Remove the RH crossmember bracket.

Fig 22: Removing RH Crossmember Bracket
Courtesy of FORD MOTOR CO.
Remove the rear transmission mount nuts and remove the crossmember.

Fig 23: Removing Rear Transmission Mount Nuts And Crossmember
Courtesy of FORD MOTOR CO.
Remove the rear transmission mount from the extension housing.

Fig 24: Removing Rear Transmission Mount From Extension Housing
Courtesy of FORD MOTOR CO.
Disconnect the wire harness from the bracket.

Fig 25: Disconnecting Wire Harness From Bracket
Courtesy of FORD MOTOR CO.
Remove the nine transmission-to-engine mounting bolts and position the wire harness bracket out of the way.

Fig 26: Removing Nine Transmission-To-Engine Mounting Bolts
Courtesy of FORD MOTOR CO.
Slide the transmission back enough to install the special tool.

Fig 27: Installing Special Tool
Courtesy of FORD MOTOR CO.
If equipped, remove the transmission-mounted parking brake.
1. Remove the transmission-mounted parking retaining bolts.
2. Keeping the vent in an upward position, remove the transmission-mounted parking brake assembly.
3. Remove and discard the transmission-mounted parking brake gasket.
  
  Fig 28: Removing Transmission-Mounted Parking Brake Gasket
  Courtesy of FORD MOTOR CO.
Disconnect the transmission fluid cooler tubes and filter housing from the case.

Fig 29: Disconnecting Transmission Fluid Cooler Tubes And Filter Housing From Case
Courtesy of FORD MOTOR CO.
If overhauling the transmission or installing a new transmission, carry out the transmission fluid cooler backflushing and cleaning. For additional information, refer to TRANSMISSION FLUID COOLER - BACKFLUSHING AND CLEANING .