Transmission - Diesel Engines: Removal

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
2. Remove the transmission fluid level indicator.
   Fig 1: Locating Transmission Fluid Level Indicator

   Courtesy of FORD MOTOR CO.
3. Remove the starter motor. For additional information, refer to STARTING SYSTEM - DIESEL ENGINE .
4. Remove the retainers and remove the starter dust shield.
   Fig 2: Locating Starter Dust Shield Retainer

   Courtesy of FORD MOTOR CO.
5. Remove and discard the 8 torque converter nuts.
   Fig 3: Locating Torque Converter Nut

   Courtesy of FORD MOTOR CO.
NOTE: If transmission disassembly is required, drain the transmission fluid.
Fig 4: Locating Transmission Drain Plug
Courtesy of FORD MOTOR CO.
6. Remove the plug and drain the transmission fluid. Install the drain plug.
   • Tighten to 18 Nm (159 lb-in).
7. Rotate the shell of the transmission vehicle harness connector counterclockwise and disconnect the transmission vehicle harness connector.
   Fig 5: Locating Transmission Vehicle Harness Connector

   Courtesy of FORD MOTOR CO.
8. Disconnect the selector lever cable end from the manual control lever, remove the 2 bolts and position the selector lever cable and bracket aside.
   Fig 6: Locating Selector Lever Cable With Mounting Bolts

   Courtesy of FORD MOTOR CO.
9. Remove the wiring harness retainer from the transmission case and position the wiring harness aside.
   Fig 7: Locating Wiring Harness Retainer

   Courtesy of FORD MOTOR CO.
NOTE: Only use hand tools when loosening the engine support insulator nuts or damage to the engine support insulator may occur.
NOTE: The RH engine support insulator studs may come out of the insulator while removing the nuts. Install new RH engine support insulator studs if the studs come out.
Fig 8: Locating RH Engine Support Insulator Nuts
Courtesy of FORD MOTOR CO.
10. Remove and discard the 4 RH engine support insulator nuts.
NOTE: Only use hand tools when loosening the engine support insulator nuts or damage to the engine support insulator may occur.
Fig 9: Locating LH Engine Support Insulator Nuts
Courtesy of FORD MOTOR CO.
11. Remove and discard the 3 LH engine support insulator nuts.

    Rear Wheel Drive (RWD) 

NOTE: When removing the crossmember, support the transmission using a heavy duty transmission jack.
NOTE: The transmission support insulator studs may come out of the transmission support insulator while removing the transmission support insulator-to-crossmember nuts. Install new transmission support insulator studs if the studs come out.
12. • Place the jack so the fluid pan does not support the weight of the transmission  .
    • Fasten a chain or ratchet strap over the top of the transmission and to both sides of the jack  .

    Failure to use a heavy duty transmission jack can result in damage to the transmission  .

    Remove the transmission support crossmember.

    RWD vehicles equipped with a slip yoke 

13. Remove the rear driveshaft. For additional information, refer to DRIVESHAFT .
14. If installing a new, remanufactured or overhauled transmission, remove and discard the 2 transmission support insulator-to-transmission bolts and remove the transmission support insulator.
    Fig 10: Locating Transmission Support Insulator-To-Transmission Bolts

    Courtesy of FORD MOTOR CO.

    RWD vehicles equipped with a fixed yoke 

NOTE: It may be necessary to tap the driveshaft yoke with a plastic or rubber soft-faced hammer if a pry area is not present on the driveshaft side.
Fig 11: Locating Rear Driveshaft Mark And Mounting Bolts
Courtesy of FORD MOTOR CO.
15. Index mark the rear driveshaft. Remove and discard the 4 bolts and position the rear driveshaft aside.
    • Support the driveshaft using mechanics wire.
16. If installing a new, remanufactured or overhauled transmission, remove and discard the 4 transmission support insulator bracket bolts and remove the transmission support insulator and bracket.
    Fig 12: Locating Transmission Support Insulator Bracket Bolts

    Courtesy of FORD MOTOR CO.

    Vehicles equipped with Four-Wheel Drive (4WD) and a manual shift transfer case 

17. Remove the transfer case linkage bolt and position the transfer case linkage aside.
    Fig 13: Locating Transfer Case Linkage Bolt

    Courtesy of FORD MOTOR CO.
18. Remove the bolt and the transfer case linkage bracket.
    Fig 14: Locating Transfer Case Linkage Bracket Bolt

    Courtesy of FORD MOTOR CO.

    4WD vehicles 

NOTE: When removing the transfer case, support the transmission using a heavy duty transmission jack.
NOTE: If the transmission is being removed for the flexplate or engine related repairs, the transfer case does not need to be separated from the transmission.
19. • Place the jack so the fluid pan does not support the weight of the transmission  .
    • Fasten a chain or ratchet strap over the top of the transmission and to both sides of the jack  .

    Failure to use a heavy duty transmission jack can result in damage to the transmission  .

    Remove the transfer case. For additional information, refer to TRANSFER CASE .

    All vehicles 

20. Remove the bolt and position the transmission fluid cooler tubes aside.
    Fig 15: Locating Transmission Fluid Cooler Tube Bolt

    Courtesy of FORD MOTOR CO.
21. Remove the lower transmission fluid filler tube bolt and position the transmission fluid filler tube aside. Remove and discard the transmission fluid filler tube O-ring.
    Fig 16: Locating Lower Transmission Fluid Filler Tube Bolt

    Courtesy of FORD MOTOR CO.
22. Remove the 11 bolts and remove the transmission from the engine dowel pins.
    Fig 17: Locating Engine Dowel Pins

    Courtesy of FORD MOTOR CO.
23. Slide the transmission back enough to install the Torque Converter Retainer and remove the transmission.
    Fig 18: Positioning Torque Converter Using Torque Converter Retainer

    Courtesy of FORD MOTOR CO.