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Section 474 (Automatic Transmission): Installation: Transmission

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
MATERIAL ITEM SPECIFICATION

Item Specification
MERCON® V Automatic Transmission Fluid XT-5-QM MERCON® V

    4X4 VEHICLES 

  1. Install the vent tube assembly.
    Fig 1: Installing Vent Tube Assembly
    G03975579Courtesy of FORD MOTOR CO.

    2. ALL VEHICLES 

    WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions may result in personal injury.
  2. Raise and position the transmission.
  3. Remove the special tool.
    Fig 2: Removing Special Tool
    G03975580Courtesy of FORD MOTOR CO.

    4. 4.0L SOHC ENGINE 

    NOTE: Align the flexplate to the converter marks made at removal.
  4. Install the transmission-to-engine screws.
    1. Install 2 M10 x 40-mm (1.6-in) screws.
    2. Install 4 M10 x 50-mm (2-in) screws.
    3. Install 2 M10 x 75-mm (3-in) screws.
      Fig 3: Installing Transmission-To-Engine Screws
      G03975581Courtesy of FORD MOTOR CO.

    5. 2.3L AND 3.0L ENGINES 

    NOTE: Align the flexplate to the converter marks made at removal.
  5. Install the screws.
    1. Install 1 M10 x 40-mm (1.6-in) screw.
    2. Install 4 M10 x 50-mm (2-in) screws.
    3. Install 2 M10 x 75-mm (3-in) screws.
      Fig 4: Installing Transmission-To-Engine Screws
      G03975582Courtesy of FORD MOTOR CO.
  6. Install the upper fluid filler tube and bracket screw.
    1. Install the upper filler tube.
    2. Install the M10 x 40-mm (1.6-in) bracket screw.
      Fig 5: Installing Upper Fluid Filler Tube And Bracket Screw
      G03975583Courtesy of FORD MOTOR CO.

    7. 2.3L ENGINE 

  7. Install the lower transmission-to-engine screws.
    Fig 6: Installing Lower Transmission-To-Engine Screws
    G03975584Courtesy of FORD MOTOR CO.
  8. Install the HO2S connector bracket.
    Fig 7: Installing HO2S Connector Bracket
    G03975585Courtesy of FORD MOTOR CO.
  9. Install the rear engine cover plate.
    Fig 8: Installing Rear Engine Cover Plate
    G03975586Courtesy of FORD MOTOR CO.

    10. 4X4 VEHICLES 

  10. Install the transfer case. For additional information, refer to TRANSFER CASE - AUTOMATIC SHIFT .

    11. ALL VEHICLES 

  11. Install the screws.
    1. Install the exhaust bracket.
    2. Install the screws.
      Fig 9: Installing Screws
      G03975587Courtesy of FORD MOTOR CO.

    12. 4X2 VEHICLES 

  12. Install the crossmember.
    • Position the crossmember.
    • Install the six bolts (three each side).
      Fig 10: Installing Crossmember - 4X2 Vehicles
      G03975588Courtesy of FORD MOTOR CO.

    13. 4X4 VEHICLES 

  13. Install the crossmember.
    1. Position the crossmember.
    2. Install the six crossmember bolts (three each side).
      Fig 11: Installing Crossmember - 4X4 Vehicles
      G03975589Courtesy of FORD MOTOR CO.

    14. ALL VEHICLES 

  14. Install the transmission mount into the crossmember and tighten the nuts.
    Fig 12: Installing Transmission Mount Into Crossmember And Tightening Nuts
    G03975590Courtesy of FORD MOTOR CO.

    15. 3.0L ENGINES 

  15. If equipped, install the rear vibration damper.
    Fig 13: Installing Rear Vibration Damper
    G03975591Courtesy of FORD MOTOR CO.

    16. 3.0L AND 4.0L SOHC ENGINES 

    CAUTION: Care should be taken not to bend or damage the cooler lines.
    NOTE: Prior to installing the cooler lines to the case, inspect the O-ring seals. If damaged, new O-ring seals must be installed.
    Fig 14: Installing Transmission Cooler Lines
    G03975592Courtesy of FORD MOTOR CO.
  16. Hold the case fitting and install the transmission cooler lines.
  17. Install four new torque converter nuts.
    • Rotate the crankshaft as needed to gain access to all the nuts.
      Fig 15: Installing Four New Torque Converter Nuts
      G03975593Courtesy of FORD MOTOR CO.

    18. 2.3L VEHICLES 

    CAUTION: When installing the torque converter nuts, the crankshaft must be rotated only in the clockwise direction, otherwise engine damage can occur. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction between the flange faces on each part. For that reason, the crankshaft sprocket can also be moved when the crankshaft pulley is turned in the counterclockwise direction.
  18. Install four new torque converter nuts.
    • Rotate the crankshaft as needed to gain access to all the nuts.
      Fig 16: Installing New Torque Converter Nuts
      G03975594Courtesy of FORD MOTOR CO.

    19. ALL VEHICLES 

  19. Install the starter motor. For additional information, refer to STARTERS article.
  20. Install the catalytic converter assembly. For additional information, refer to EXHAUST SYSTEM .
  21. Position the transmission wiring harness in place.
    1. Clip harness to the shift cable bracket.
    2. Clip harness retainer to the case.
      Fig 17: Positioning Transmission Wiring Harness In Place
      G03975595Courtesy of FORD MOTOR CO.
  22. Connect the transmission wiring harness.
    1. Connect the transmission connector.
    2. Connect the intermediate shaft speed (ISS) sensor.
    3. Connect the digital transmission range (TR) sensor connector.
    4. Connect the output shaft speed (OSS) sensor.
      Fig 18: Connecting Transmission Wiring Harness
      G03975596Courtesy of FORD MOTOR CO.
  23. Install the shift cable.
    1. Connect the shift cable to manual control lever.
    2. Connect the shift cable to the bracket.
      Fig 19: Installing Shift Cable
      G03975597Courtesy of FORD MOTOR CO.
    24. NOTE: Align the driveshaft yoke and the axle shaft marks made at removal to maintain driveline balance.
    Fig 20: Identifying Driveshaft Flange-To-Pinion Flange Alignment Marks
    G03888574Courtesy of FORD MOTOR CO.
  24. Align and install the rear driveshaft.
  25. Install the driveshaft bolts.
    Fig 21: Installing Driveshaft Bolts
    G03975599Courtesy of FORD MOTOR CO.
  26. Use the following guidelines for installing the in-line transmission fluid 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 an in-line fluid filter, install a new in-line fluid filter kit.
    • 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.

      Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit. For additional information, refer to TRANSMISSION FLUID IN-LINE FILTER .

    27. 4.0L SOHC VEHICLES 

  27. Install the transmission fill tube and indicator as an assembly.
    Fig 22: Installing Transmission Fill Tube And Indicator
    G03975600Courtesy of FORD MOTOR CO.

    28. ALL VEHICLES 

    NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer must be notified that they may experience slightly different upshifts (either soft or firm) and that this is a temporary condition. The vehicle will eventually return to normal operating condition.
  28. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  29. Fill the transmission with clean automatic transmission fluid to the specified level.
  30. Check the transmission for correct operation.
  31. Verify that the shift cable is correctly adjusted. For additional information, refer to TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS .
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