Transmission - Gasoline Engines: Installation

All vehicles 

NOTE: Prior to installation of the transmission, the torque converter pilot hub must be lubricated or damage to the torque converter or the engine crankshaft can occur.
Fig 1: Locating Torque Converter Pilot Hub
Courtesy of FORD MOTOR CO.
1. Lubricate the torque converter pilot hub with multi-purpose grease.
2. Rotate the torque converter so the green or orange paint daub on the converter is in the 12 o'clock position.
3. If the Torque Converter Retainer has not been installed during the assembly of the transmission, install the Torque Converter Retainer to hold the torque converter in place while moving and positioning the transmission in place. Once the transmission is in place, prior to bolting it to the engine, remove the Torque Converter Retainer.
   Fig 2: Installing Torque Converter Retainer

   Courtesy of FORD MOTOR CO.
4. Install a new transmission fluid filler tube O-ring.
   Fig 3: Locating Transmission Filler Tube O-Ring

   Courtesy of FORD MOTOR CO.
5. Position the transmission in place. While raising the transmission up into the engine compartment, align the transmission fluid filler tube with the stub tube on the transmission using the transmission fluid level indicator as a guide.

   While installing the transmission to the engine, align the torque converter studs with the mounting holes in the flexplate.

   Fig 4: Aligning Transmission Filler Tube With Stub Tube On Transmission

   Courtesy of FORD MOTOR CO.
6. Install the 9 transmission-to-engine bolts.
   • Tighten to 47 Nm (35 lb-ft).
     Fig 5: Locating Transmission-To-Engine Mounting Bolts

     Courtesy of FORD MOTOR CO.
7. Using a suitable tool, rotate the crankshaft pulley to gain access to the torque converter-to-flexplate nuts.
   Fig 6: Rotating Crankshaft Pulley To Gain Access To Torque Converter-To-Flexplate Nuts

   Courtesy of FORD MOTOR CO.
8. Install the 6 new torque converter-to-flexplate nuts.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 7: Locating Torque Converter-To-Flexplate Nuts

     Courtesy of FORD MOTOR CO.
9. Install the cylinder block opening cover.
   Fig 8: Locating Cylinder Block Opening Cover

   Courtesy of FORD MOTOR CO.
10. Position the steering damper and install the steering damper-to-frame bolt and nut.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 9: Locating Steering Damper-To-Frame Bolt And Nut

      Courtesy of FORD MOTOR CO.
11. Install the starter motor. For additional information, refer to STARTING SYSTEM - GASOLINE ENGINES .
12. If equipped with dual generators, rotate the tensioner and install the outer accessory drive belt onto the crankshaft pulley.
    Fig 10: Locating Outer Accessory Drive Belt From Crankshaft Pulley

    Courtesy of FORD MOTOR CO.
13. Install the front transmission fluid cooler tube.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 11: Locating Transmission Fluid Cooler Outlet Tube

      Courtesy of FORD MOTOR CO.
14. Install the rear transmission fluid cooler tube.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 12: Locating Transmission Fluid Cooler Inlet Tube

      Courtesy of FORD MOTOR CO.
15. Install the flexplate inspection cover.
    1. Position the flexplate inspection cover.
    2. Install the flexplate inspection cover bolts.
       • Tighten to 34 Nm (25 lb-ft).
         Fig 13: Locating Flexplate Inspection Cover Bolts

         Courtesy of FORD MOTOR CO.
16. Install the transmission insulator and retainer extension housing bolts.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 14: Locating Bolts And Transmission Insulator And Retainer From Extension Housing

      Courtesy of FORD MOTOR CO.
17. If required, install a new transmission insulator and retainer stud.
    • Tighten to 75 Nm (55 lb-ft).
18. Install the transmission support crossmember. For additional information, refer to FULL FRAME AND BODY MOUNTING - F250-F550 SUPER DUTY .
19. Connect the fuel line bracket and install the fuel line bracket nut.
    • Tighten to 12 Nm (106 lb-in).
      Fig 15: Disconnecting Fuel Line Bracket

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in the illustration, LH similar.
Fig 16: Locating RH And LH Wire Harness From Side Of Transmission
Courtesy of FORD MOTOR CO.
20. Connect the RH and LH wiring harness to the side of the transmission.
21. Connect the Output Shaft Speed (OSS) sensor.
    Fig 17: Locating Output Shaft Speed (OSS) Sensor Connector

    Courtesy of FORD MOTOR CO.
22. Connect the Turbine Shaft Speed (TSS)/intermediate shaft speed sensor.
    Fig 18: Locating Intermediate Shaft Speed Sensor Connector

    Courtesy of FORD MOTOR CO.
23. Connect the transmission vehicle harness connector.
    • Tighten to 5 Nm (44 lb-in).
      Fig 19: Locating Transmission Vehicle Harness Connector

      Courtesy of FORD MOTOR CO.
NOTE: If the vehicle is equipped with a Power Take-Off (PTO) unit, all or part of the PTO  unit will need to be installed.
NOTE: To prevent selector lever cable damage, do not apply force to the selector lever cable assembly between the manual control lever and the selector lever cable bracket.
24. Connect the selector lever cable.
    1. Install the selector lever cable housing bracket and selector lever cable housing bracket bolts.
       • Tighten to 48 Nm (35 lb-ft).
    2. Install the selector lever cable to the manual control lever.
       Fig 20: Identifying Selector Lever Cable To Manual Control Lever

       Courtesy of FORD MOTOR CO.

    Four-Wheel Drive (4WD) vehicles 

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

    Rear Wheel Drive (RWD) vehicles 

26. Install the rear driveshaft. For additional information, refer to DRIVESHAFT .

    All vehicles 

27. Install the exhaust pipe between the exhaust manifold and the exhaust flange. For additional information, refer to EXHAUST SYSTEM .
28. Connect the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
NOTE: Use the following guidelines for the in-line transmission fluid filter:
• If the transmission was overhauled and the vehicle was equipped with an in-line transmission fluid filter, install a new in-line transmission fluid filter.
• If the transmission was overhauled and the vehicle was not equipped with the in-line transmission fluid filter, install a new in-line transmission fluid filter.
• If the transmission is being installed for a non-internal repair, do not install an in-line transmission fluid filter or transmission fluid filter kit.
• If installing a new or a Ford-authorized remanufactured transmission, install an in-line transmission fluid filter.
29. Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit.
30. With the installation of an overhauled or remanufactured transmission, the transmission fluid cooler tubes must be cleaned and back-flushed, and then the transmission fluid flow verified in order to prevent repeat repairs. For additional information, refer to TRANSMISSION FLUID COOLER BACKFLUSHING AND CLEANING  and TRANSMISSION FLUID COOLER .
31. Adjust the selector lever cable. Verify that the vehicle starts in PARK and NEUTRAL and the reverse lamps illuminate in REVERSE. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS .
32. With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level, and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved (transmission fluid should be in the hot range cross-hatched area of the transmission fluid level indicator).
33. For vehicles equipped with a PTO  assembly, prior to installing the transmission, the PTO  assembly must be flushed and cleaned to remove any foreign material. Failure to remove foreign material from the PTO  assembly may result in subsequent transmission concerns.