Transmission - All Wheel Drive (AWD): Installation

WARNING: This page is about a different car, the 2013 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Prior to installing a new, re-manufactured or overhauled transmission, the transmission fluid cooler tubes must be cleaned, otherwise transmission failure may occur.

NOTE: Prior to installing a new, re-manufactured or overhauled transmission, flush out the cooler and cooler tubes. REFER to TRANSMISSION FLUID COOLER BACKFLUSHING AND CLEANING .

If removed, inspect the transmission mounted transmission fluid cooler tube backing rings and seals for damage and install new backing rings or seals if necessary. Lubricate the transmission mounted transmission fluid cooler tube seals with clean Motorcraft® MERCON® LV Automatic Transmission Fluid and install the backing rings and seals on the transmission mounted transmission fluid cooler tubes.

Item	Service Part Number	Description
1	7D258	Seal
2	7J324	Backing ring

Fig 1: Identifying Transmission Mounted Transmission Fluid Cooler Tube Backing Ring And Seal

Courtesy of FORD MOTOR CO.

If removed, position the transmission fluid cooler thermal bypass valve and transmission mounted transmission fluid cooler tube assembly in place and install the nuts.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 2: Locating Transmission Mounted Transmission Fluid Cooler Tube Assembly Nut
  Courtesy of FORD MOTOR CO.
If removed, install new transmission mounted transmission fluid cooler tube bolts.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 3: Locating Transmission Mounted Transmission Fluid Cooler Tube Bolts
  Courtesy of FORD MOTOR CO.
Lubricate the torque converter pilot hub with Multi-Purpose Grease.
NOTE: If the transmission is not positioned on the dowel pins, damage to the transmission may occur.

If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.

Fig 4: Locating Engine Block Dowel Pins
Courtesy of FORD MOTOR CO.
Using 209-00152, support the transmission.

Fig 5: Support Transmission Using 209-00152
Courtesy of FORD MOTOR CO.
Position the transmission behind the engine and remove 307-346 T97T-7902-A.

Position the transmission on the dowel pins and install the lower torque converter housing bolts.

If equipped.

Tighten to 48 Nm (35 lb-ft).

Install the transmission support insulator bracket, the nuts and the bolt.
- Tighten the bolt to 80 Nm (59 lb-ft).
- Tighten the nuts to 63 Nm (46 lb-ft).
  
  Fig 6: Locating Transmission Support Insulator Bracket Nuts And Bolt
  Courtesy of FORD MOTOR CO.
Remove 303-F072 and 303-1454.

Fig 7: Supporting Engine And Transmission Using Tool
Courtesy of FORD MOTOR CO.
Remove 303-1245 from the LH cylinder head.

Fig 8: Installing (303-1245) Tool On LH Cylinder Head
Courtesy of FORD MOTOR CO.
Install the transmission fluid cooler tubes in the transmission fluid cooler thermal bypass valve.

Fig 9: Locating Transmission Fluid Cooler Tubes
Courtesy of FORD MOTOR CO.
Install the secondary latches on the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.

Fig 10: Locating Transmission Fluid Cooler Tube Secondary Latches
Courtesy of FORD MOTOR CO.
NOTE: Use only the specified bolts for the torque converter. Standard length fasteners may bottom out and damage the torque converter clutch apply surface.

Install 3 new torque converter bolts (-W714722-).
- Tighten to 55 Nm (41 lb-ft).
- Install the first torque converter bolt in the slotted hole on the flexplate.
  
  Fig 11: Locating Torque Converter Bolt
  Courtesy of FORD MOTOR CO.
Install the inspection cover and the 2 fasteners.

Fig 12: Locating Inspection Cover
Courtesy of FORD MOTOR CO.
NOTE: The circlips are unique in size and shape for each shaft. Make sure to use the specified circlip for the application or vehicle damage may occur.

Install the correct new circlip on the inboard stub shaft.

Fig 13: Locating Inboard Stub Shaft Circlip
Courtesy of FORD MOTOR CO.
NOTE: If the transmission has been replaced or overhauled, the halfshaft seals do not need to be replaced.

Install a new LH halfshaft seal. REFER to, HALFSHAFT SEAL - LH .
NOTE: Remove the seal protector before the halfshaft is installed completely.

Using part: AA5P-4N206-A.
NOTE: After insertion, pull the halfshaft inner end to make sure the circlip is locked.

NOTE: Insert shaft until circlip is fully seated. When checking if circlip is seated do not pull on CV joint or damage can result
Install the PTU . REFER to TRANSFER CASE - POWER TRANSFER UNIT (PTU) .
Install the front subframe. REFER to SUBFRAME - FRONT .
Install the top torque converter housing bolts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 14: Locating Top Torque Converter Housing Bolts
  Courtesy of FORD MOTOR CO.
Connect the transmission electrical connector and install the wiring harness fastener on the main control cover stud.

Fig 15: Locating Transmission Electrical Connector And Wiring Harness Fastener
Courtesy of FORD MOTOR CO.
Connect the 2 wiring harness retainers on the transmission.

Fig 16: Locating Transmission Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Install the ground strap and nut on the main control cover stud bolt.
- Tighten to 11 Nm (97 lb-in).
Install the rear starter stud bolt.
- Tighten to 27 Nm (20 lb-ft).
Attach the starter wire terminals and install the 2 nuts.
- Tighten the B+ terminal nut to 12 Nm (106 lb-in).
- Tighten the S-terminal nut to 5 Nm (44 lb-in).
  
  Fig 17: Locating Starter Wire Terminals Nuts
  Courtesy of FORD MOTOR CO.
Install the starter motor solenoid cover.

Fig 18: Locating Starter Motor Solenoid Cover
Courtesy of FORD MOTOR CO.
Attach the wiring harness pin-type retainer and connect the selector lever cable to the selector lever cable bracket.

Fig 19: Locating Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Place the selector lever in DRIVE.
Place the manual control lever in DRIVE.
1. Rotate the manual control lever clockwise until it stops.
2. Rotate the manual control lever counterclockwise one detent.
  
  Fig 20: Rotating Manual Control Lever
  Courtesy of FORD MOTOR CO.
Unlock the selector lever cable adjuster by sliding the locking tab over.

Fig 21: Unlocking Selector Lever Cable Adjuster
Courtesy of FORD MOTOR CO.
Slide the cable end forward or backward to align it with the manual control lever.

Fig 22: Aligning Manual Control Lever
Courtesy of FORD MOTOR CO.
With the adjuster locking tab released, connect the selector lever cable end to the manual control lever.

Fig 23: Locating Adjuster Locking Tab Released
Courtesy of FORD MOTOR CO.
Slide the release tab back to lock the adjuster.

Fig 24: Locking Release Tab Adjuster
Courtesy of FORD MOTOR CO.
Install the upper intake manifold. For 3.5L Ti-VCT refer to ENGINE MECHANICAL - 3.5L TI-VCT . For 3.7L Ti-VCT refer to Section 303-01C.
Install the battery tray. REFER to BATTERY AND BATTERY TRAY - EXPLODED VIEW .
Install the ACL assembly. REFER to INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW .
Fill with clean Motorcraft® MERCON® LV Automatic Transmission Fluid to the correct level. Refer to TRANSMISSION FLUID DRAIN AND REFILL .
After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.
If a replacement transmission assembly is being installed or a new solenoid body is installed, the solenoid body strategy will need to be updated. Refer to SOLENOID BODY STRATEGY DOWNLOAD .