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Section 62 (Automatic Transmission -- F250-F550 Super Duty): Installation: Transmission: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles 

CAUTION: Prior to installation of a new or overhauled transmission, the fluid cooler lines must be cleaned. Otherwise transmission failure can occur.
    CAUTION: Prior to installation of a new or overhauled transmission, a new transmission fluid cooler remote filter element must be installed. Otherwise transmission failure can occur.
  1. If necessary, install a new transmission fluid cooler remote filter element. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING .
    2. CAUTION: Prior to installation of the assembly, the torque converter pilot hub must be correctly lubricated or damage to the torque converter or the engine crankshaft can occur.
    Fig 1: Lubricating Torque Converter Pilot Hub
    G03889591Courtesy of FORD MOTOR CO.
  2. Lubricate the torque converter pilot hub with multi-purpose grease.
  3. Rotate the torque converter so the green or orange paint daub on the converter is in the 12 o'clock position.
  4. If the special tool has not been installed during the assembly of the transmission, install the special tool 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 special tool.
    Fig 2: Identifying Special Torque Converter Tool
    G03889231Courtesy of FORD MOTOR CO.
  5. Position the transmission in place. While raising the transmission up into the engine compartment, align the fluid filler tube with the stub tube on the transmission using the 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 3: Aligning Fluid Filler Tube With Stub Tube On Transmission
    G03889593Courtesy of FORD MOTOR CO.
  6. Install nine transmission-to-engine bolts.
    Fig 4: Installing Transmission-To-Engine Bolts
    G03889631Courtesy of FORD MOTOR CO.
  7. Using a suitable strap wrench to rotate the crankshaft and pulley, install the new torque converter-to-flexplate nuts.
    Fig 5: Torque Converter-To-Flexplate Nuts - With Torque Specifications
    G03886114Courtesy of FORD MOTOR CO.
  8. Install the cylinder block opening cover.
    Fig 6: Identifying Cylinder Block Torque Converter Cover
    G03889219Courtesy of FORD MOTOR CO.
  9. If equipped with dual generators, rotate the tensioner and install the outer accessory drive belt onto the crankshaft pulley.
    Fig 7: Installing Outer Accessory Drive Belt Onto Crankshaft Pulley
    G03922813Courtesy of FORD MOTOR CO.
  10. Install the flexplate inspection cover and bolts.
    Fig 8: Flywheel Inspection Plate - With Torque Specification
    G03885467Courtesy of FORD MOTOR CO.
  11. Install the starter motor. For additional information, refer to STARTING SYSTEM - GASOLINE ENGINES .
  12. Install the front transmission fluid cooler tube.
    Fig 9: Installing Front Transmission Fluid Cooler Tube
    G03909381Courtesy of FORD MOTOR CO.
  13. Install the rear transmission fluid cooler tube.
    Fig 10: Installing Rear Transmission Fluid Cooler Tube
    G03909382Courtesy of FORD MOTOR CO.

    14. 4x4 vehicles 

  14. Support the extension housing with a jack stand and remove the transmission jack.

    15. 4x2 vehicles 

  15. Install the transmission mount.
    Fig 11: Installing Transmission Mount
    G03889602Courtesy of FORD MOTOR CO.
  16. Position the crossmember to the transmission mount and loosely install the nut.
    Fig 12: Locating Crossmember To Transmission Mount
    G03889185Courtesy of FORD MOTOR CO.
  17. Install the LH crossmember bolts.
    Fig 13: Installing LH Crossmember Bolts
    G03923154Courtesy of FORD MOTOR CO.
  18. Install the RH crossmember bolts.
    Fig 14: Installing RH Crossmember Bolts
    G03922786Courtesy of FORD MOTOR CO.
  19. Install the bracket and loosely install the bolts.
    1. Install the bracket.
    2. Loosely install the bolts.
      Fig 15: Installing Bracket And Bolts
      G03922662Courtesy of FORD MOTOR CO.
  20. Tighten the RH crossmember bolts.
    Fig 16: Tightening RH Crossmember Bolts
    G03922663Courtesy of FORD MOTOR CO.
  21. Tighten the rear insulator nuts.
    Fig 17: Rear Transmission Mount Insulator Nuts - With Torque Specification
    G03889190Courtesy of FORD MOTOR CO.

    22. All vehicles 

  22. Connect the fuel line bracket and install the nut.
    Fig 18: Connecting Fuel Line Bracket
    G03923159Courtesy of FORD MOTOR CO.
    23. NOTE: RH shown, LH similar.
    Fig 19: Connecting RH And LH Wiring Harness To Side Of Transmission
    G03909016Courtesy of FORD MOTOR CO.
  23. Connect the RH and LH wiring harness to the side of the transmission.
  24. Connect the output shaft speed (OSS) sensor electrical connector.
    Fig 20: Identifying Output Shaft Speed (OSS) Sensor Electrical Connector
    G03889074Courtesy of FORD MOTOR CO.
  25. Connect the intermediate shaft and turbine shaft combination speed sensor electrical connector.
    Fig 21: Identifying Intermediate Shaft And Turbine Shaft Combination Speed Sensor Electrical Connector
    G03889065Courtesy of FORD MOTOR CO.
  26. Connect the solenoid body electrical connector.
    Fig 22: Solenoid Body Electrical Connector - With Torque Specification
    G03889059Courtesy of FORD MOTOR CO.
    27. 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.
  27. Connect the shift cable.
    1. Install the cable housing bracket.
    2. Install the shift cable to the manual lever.
      Fig 23: Installing Shift Cable To Manual Lever
      G03909392Courtesy of FORD MOTOR CO.

    28. 4x2 vehicles 

  28. Reconnect the wire harness to the frame.
    Fig 24: Locating Wire Harness At Rear Of Crossmember
    G03908863Courtesy of FORD MOTOR CO.
  29. Vehicles equipped with a gas engine, install the exhaust pipe between the exhaust manifold and the exhaust flange. For additional information, refer to EXHAUST SYSTEM .

    30. 4x4 vehicles 

  30. If equipped, install the transfer case. For additional information, refer to TRANSFER CASE .

    31. 4x2 vehicles 

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

    32. All vehicles 

  32. Connect the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
    33. NOTE: Use the following guidelines for the in-line transmission filter:
    • If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a new in-line fluid filter.
    • If the transmission was overhauled and the vehicle was not equipped with the in-line fluid filter, install a new in-line fluid filter.
    • If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter kit.
    • If installing a new or a Ford-authorized remanufactured transmission, install the in-line transmission fluid filter that is supplied.
  33. Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit.
  34. Adjust the shift linkage. 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 .
  35. 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.
  36. 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 fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).
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