Automatic Transmission: Removal: Transmission

SPECIAL TOOL DESCRIPTION

Retainer, Torque Converter
307-346 (T97T-7902-A)

CAUTION: Whenever a transmission has been disassembled to install new parts, the transmission fluid cooler tubes must be cleaned and backflushed using a suitable torque converter/fluid cooler cleaner. A new oil-to-air (OTA) cooler must also be installed.
When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the torque converter and fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back into service.

NOTE: After the transmission is removed for a major overhaul, it is important to completely clean all transmission components, including torque converter, cooler inlet tube, main control valve body, clutches and all coasting booster valve shuttle balls after any transmission service that generates contamination. These contaminants are a major cause for recurring transmission concerns and must be removed from the system before the transmission is returned to service.

The cleaning of foreign material from the direct clutch check ball is often omitted. This omission can lead to a repeat servicing of the transmission.

A new OTA cooler must be installed under the following condition. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING .

Evidence of broken transmission components or fluid contamination found due to the following transmission or converter failure modes:
- Major metallic failure
- Multiple clutches or clutch plate failure
- Sufficient component wear which results in metallic contamination

Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .

WARNING: If equipped with fire suppression system, depower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .

NOTE: Only if transmission disassembly or replacement is required, drain the transmission fluid. For additional information, refer to FLUID PAN, GASKET AND FILTER .

Drain the transmission fluid.
- Loosen the transmission fluid pan bolts and allow the fluid to drain. After fluid has drained remove the bolts and the pan and drain the remaining fluid that is in the pan.
  
  Fig 1: Locating Transmission Fluid Pan Bolts
  Courtesy of FORD MOTOR CO.
Install the transmission fluid pan and the old gasket.
1. Position the transmission fluid pan gasket.
2. Position the transmission fluid pan.
  
  Fig 2: Positioning Fluid Pan With Gasket
  Courtesy of FORD MOTOR CO.

NOTE: To maintain the initial driveshaft balance, mark the rear driveshaft yoke and the axle pinion flange so they can be installed in their original positions.

Fig 3: Identifying Driveshaft Bolts

Courtesy of FORD MOTOR CO.

Mark the rear driveshaft yoke and the axle pinion flange and remove the 4 bolts.
Index-mark the driveshaft and extension housing. Separate the driveshaft from the transmission.

Fig 4: Marking Driveshaft And Extension Housing
Courtesy of FORD MOTOR CO.
Remove the torque converter access cover plug at the left rear engine block.

Fig 5: Locating Rubber Access Plug
Courtesy of FORD MOTOR CO.
Remove the torque converter access cover.
1. Remove the bolts.
2. Remove the inspection cover.
3. Remove the bolt.
  
  Fig 6: Removing Torque Converter Access Cover Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Make an identifying mark on the torque converter stud and the flexplate for correct alignment during assembly.

Fig 7: Locating Flexplate-To-Torque Converter Nuts

Courtesy of FORD MOTOR CO.

Remove and discard the 4 torque converter-to-flexplate nuts.
Disconnect the RH HO2S connector.

Fig 8: Disconnecting RH HO2S Connector
Courtesy of FORD MOTOR CO.
Disconnect the RH catalyst monitor connector.

Fig 9: RH Catalyst Monitor Connector
Courtesy of FORD MOTOR CO.
Remove the bolts from the RH exhaust flange.

Fig 10: Removing Bolts From RH Exhaust Flange
Courtesy of FORD MOTOR CO.
Remove the bolts and the RH catalytic converter.

Fig 11: Removing Bolts And RH Catalytic Converter
Courtesy of FORD MOTOR CO.
Disconnect the LH HO2S connector.

Fig 12: Identifying LH HO2S Connector
Courtesy of FORD MOTOR CO.
Disconnect the LH catalyst monitor connector.

Fig 13: LH Catalyst Monitor Connector
Courtesy of FORD MOTOR CO.
Remove the bolts from the LH exhaust flange.

Fig 14: Removing Bolts From LH Exhaust Flange
Courtesy of FORD MOTOR CO.
Remove the bolts and the LH catalytic converter.

Fig 15: Removing Bolts And LH Catalytic Converter
Courtesy of FORD MOTOR CO.

NOTE: Make a reference mark on the shift cable linkage to the transmission.

Fig 16: Disconnecting Selector Lever Cable

Courtesy of FORD MOTOR CO.

Disconnect the selector lever cable.
Remove the selector lever cable bracket and position aside.

Fig 17: Removing Selector Lever Cable Bracket
Courtesy of FORD MOTOR CO.
Remove the ground wire.

Fig 18: Removing Ground Wire
Courtesy of FORD MOTOR CO.
Remove the starter electrical connector cap.

Fig 19: Removing Starter Electrical Connector Cap
Courtesy of FORD MOTOR CO.
Disconnect the electrical connectors.

Fig 20: Disconnecting Electrical Connectors
Courtesy of FORD MOTOR CO.
Remove the 3 starter bolts and the starter.

Fig 21: Removing Starter Bolts And Starter
Courtesy of FORD MOTOR CO.

NOTE: The case connectors must be held in place to prevent them from moving.

Fig 22: Disconnecting Transmission Fluid Cooler Tubes

Courtesy of FORD MOTOR CO.

Disconnect the transmission fluid cooler tubes.
Remove the cooler line bracket and position aside.

Fig 23: Removing Cooler Line Bracket
Courtesy of FORD MOTOR CO.
Position a suitable jack under the transmission. Secure the transmission to the jack with safety straps.
Remove the rear transmission insulator nuts.

Fig 24: Removing Rear Transmission Insulator Nuts
Courtesy of FORD MOTOR CO.
Remove the RH side crossmember bolts.

Fig 25: Removing RH Side Crossmember Bolts
Courtesy of FORD MOTOR CO.
Remove the LH side crossmember bolt.

Fig 26: Removing LH Side Crossmember Bolt
Courtesy of FORD MOTOR CO.
Remove the bolts and remove the parking cable bracket and position aside.

Fig 27: Removing Bolts And Parking Cable Bracket
Courtesy of FORD MOTOR CO.

NOTE: The crossmember is a press fit in the crossmember pocket, it may be necessary to pry the crossmember out of the crossmember pocket. Be careful not to damage the crossmember.

Fig 28: Removing Lower RH Side Of Crossmember

Courtesy of FORD MOTOR CO.

Lower the RH side of the crossmember.

NOTE: The crossmember is a press fit in the crossmember pocket, it may be necessary to pry the crossmember out of the crossmember pocket. Be careful not to damage the crossmember.

Fig 29: Removing Crossmember

Courtesy of FORD MOTOR CO.

Lower the LH side of the crossmember and remove the crossmember.
Remove the rear transmission insulator.

Fig 30: Removing Rear Transmission Insulator
Courtesy of FORD MOTOR CO.

NOTE: It is not necessary to disconnect the transmission harness from all the transmission sensors at this time, the harness will come out with the transmission.

Fig 31: Disconnecting Wire Harness Connectors And Filler Tube

Courtesy of FORD MOTOR CO.

Disconnect the wire harness connectors and remove them from the filler tube.
Remove the bolt.

Fig 32: Removing Bolt
Courtesy of FORD MOTOR CO.
Position the fluid filler tube aside.

Fig 33: Positioning Fluid Filler Tube Aside
Courtesy of FORD MOTOR CO.
Remove the transmission retaining bolts.

Fig 34: Removing Transmission Retaining Bolts
Courtesy of FORD MOTOR CO.
Separate the transmission from the engine and lower. Partially lower the transmission from under the vehicle.
Disconnect the electrical connectors.
1. Remove the catalyst monitor connector retainer from the stud.
2. Disconnect the transmission solenoid body electrical connector.
  
  Fig 35: Disconnecting Transmission Solenoid Body Electrical Connector
  Courtesy of FORD MOTOR CO.
Disconnect the electrical connectors and remove the wire harness from the transmission.
1. Disconnect the digital TR sensor electrical connector.
2. Disconnect the output shaft speed (OSS) sensor electrical connector.
3. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
- Remove the catalyst monitor connector retainer from the stud.
- Disconnect the wire harness retainers and remove the harness.
  
  Fig 36: Identifying Transmission Electrical Connectors
  Courtesy of FORD MOTOR CO.

WARNING: The torque converter is heavy and can result in injury if it falls out of the transmission. Secure the torque converter in the transmission.

Fig 37: Holding Converter In Housing Using Special Tool (307-346)

Courtesy of FORD MOTOR CO.

Leaving the transmission in a horizontal position, slide it back far enough to install the special tool. Install the special tool.

NOTE: Make sure the special tool is in place and the transmission is securely fastened to the transmission jack before tilting the transmission.

Lower the transmission from under the vehicle.
Carry out the transmission fluid cooler-backflushing and cleaning if the transmission is being overhauled or installing a new or remanufactured transmission. For additional information, refer to TRANSMISSION FLUID COOLER TUBES - BACKFLUSHING AND CLEANING .