Transmission - Diesel Engines

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	High Lift Transmission Jack	014-00942

All vehicles 

1. Using the transmission jack, raise and position the transmission to the engine and clutch.
2. Install the 8 transmission-to-engine bolts.
   • Tighten to 63 Nm (46 lb-ft).
3. Position the crossmember in the vehicle. Install the 3 LH crossmember bolts.
   • Tighten to 70 Nm (52 lb-ft).
Fig 1: Left Crossmember Nuts
Courtesy of FORD MOTOR CO.
4. Install the 4 RH crossmember nuts.
   • Tighten to 70 Nm (52 lb-ft).
Fig 2: Right Crossmember Nuts
Courtesy of FORD MOTOR CO.
NOTE: The transmission mount studs may have come out of the insulator when the nuts were removed. Install new insulator studs if they came out during removal.
5. Install the 2 transmission mount nuts.
   • Tighten the studs to 75 Nm (55 lb-ft).
   • Tighten the nuts to 81 Nm (60 lb-ft).
Fig 3: Transmission Mount Nuts
Courtesy of FORD MOTOR CO.
6. Attach the wire harness to the crossmember.
7. Remove the transmission jack.
8. Connect the transmission cooler tubes.
   • Tighten to 27 Nm (20 lb-ft).
Fig 4: Transmission Cooling Tubes
Courtesy of FORD MOTOR CO.
9. Install the clutch slave cylinder.
   • Rotate the clutch slave cylinder clockwise 45 degrees to lock in position.
Fig 5: Clutch Slave Cylinder
Courtesy of FORD MOTOR CO.
10. Install the transfer case, if equipped. For additional information, refer to TRANSFER CASE article.
    • If the transfer case control lever assembly was removed from the transmission, it must be correctly aligned.
11. Install the skid plate, if equipped.
NOTE: Make sure the index marks made during removal are aligned.
NOTE: Install new bolts.
12. Connect the driveshaft.
    • Tighten to 111 Nm (82 lb-ft).
13. Install any power take-off (PTO) equipment, if equipped.
Fig 6: Fuel Line Bracket
Courtesy of FORD MOTOR CO.
14. Connect the reverse lamp switch electrical connector.
Fig 7: Reverse Lamp Switch Electrical Connector
Courtesy of FORD MOTOR CO.
15. Connect the wiring harness to the transmission.
16. Refill the transmission to specification.
    • Refill the transmission with clean transmission fluid.
17. Install the 2 bolts that attach the shift lever to the transfer case.
    • Tighten to 35 Nm (26 lb-ft).
CAUTION: Do not use a silicone sealing compound.
NOTE: Do not wait longer than 10 minutes to tighten the 4 bolts due to the rapid cure time of the sealant.
18. Install the gearshift lever and shift housing assembly.
    • Tighten to 35 Nm (26 lb-ft).
    • Apply Gasket Maker to the shift housing and the main case.
Fig 8: Locating Shift Housing Bolts & Shift Housing
Courtesy of FORD MOTOR CO.
19. Install the lower shift lever boot.
20. Install the upper gearshift lever.
    • Tighten to 35 Nm (26 lb-ft).
21. Install the 4 shift lever boot screws.
Fig 9: Locating Gearshift Lever Boot Screws
Courtesy of FORD MOTOR CO.

Vehicles with a manual shift transfer case 

22. Verify the shift sequence from 2H to 4L to 2H.