Automatic Transmission: Installation: Transmission

Special Tools

Illustration	Tool Name	Tool Number
	Retainer, Torque Converter	307-346 (T97T-7902-A)

Material

Item	Specification
MERCON® V Automatic Transmission Fluid XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada)	MERCON® V

WARNING: Secure the torque converter in the transmission during removal or installation. The torque converter is heavy and may result in injury if it falls out of the transmission. Failure to follow this instruction may result in serious personal injury.
1. Install the special tool.
Fig 1: Holding Converter In Housing Using Special Tool (307-346)
Courtesy of FORD MOTOR CO.
2. Position and secure the transmission on a suitable high-lift transmission jack.
3. Connect the electrical connectors and install the wire harness on the transmission.
   1. Connect the digital transmission range (TR) sensor electrical connector.
   2. Connect the output shaft speed (OSS) and turbine shaft speed (TSS) sensor electrical connectors.
   3. Install the catalyst monitor connector retainer to the stud.
      • Connect the wire harness retainers.
Fig 2: Identifying Transmission Electrical Connectors
Courtesy of FORD MOTOR CO.
4. Connect the electrical connectors.
   1. Install the catalyst monitor connector retainer to the stud.
   2. Connect the transmission solenoid body electrical connector.
Fig 3: Catalyst Monitor Connector Retainer & Transmission Solenoid Body Electrical Connector
Courtesy of FORD MOTOR CO.
5. Raise and position the transmission to the vehicle.
   • Align the balancing marks on the converter stud and the flexplate bolt hole.
6. Remove the special tool.
Fig 4: Holding Converter In Housing Using Special Tool (307-346)
Courtesy of FORD MOTOR CO.
7. Install the transmission retaining bolts.
   • Tighten to 48 Nm (35 lb-ft).
Fig 5: Transmission Retaining Bolts
Courtesy of FORD MOTOR CO.
8. Install the 4 torque converter nuts.
   • Tighten to 36 Nm (27 lb-ft).
Fig 6: Torque Converter-To-Flexplate Nut
Courtesy of FORD MOTOR CO.
9. Install the rubber access plug.
Fig 7: Locating Rubber Access Plug
Courtesy of FORD MOTOR CO.
10. Install the transmission inspection cover.
    1. Position the transmission inspection cover.
    2. Install the 2 bolts.
       • Tighten to 35 Nm (26 lb-ft).
    3. Install the bolt for the separator plate.
       • Tighten to 35 Nm (26 lb-ft).
Fig 8: Transmission Inspection Cover & Bolts
Courtesy of FORD MOTOR CO.
11. Install the fluid filler tube.
Fig 9: Fluid Filler Tube
Courtesy of FORD MOTOR CO.
12. Install the transmission filler tube bolt.
    • Tighten to 48 Nm (35 lb-ft).
Fig 10: Transmission Filler Tube Bolt
Courtesy of FORD MOTOR CO.
13. Install the rear transmission insulator.
    • Tighten to 90 Nm (66 lb-ft).
Fig 11: Rear Transmission Insulator Bolts
Courtesy of FORD MOTOR CO.
14. Position the LH side of the crossmember into the crossmember pocket and loosely install the bolts.
Fig 12: LH Side Crossmember
Courtesy of FORD MOTOR CO.
15. Position the RH side of the crossmember into the crossmember pocket and loosely install the bolts.
Fig 13: RH Side Crossmember
Courtesy of FORD MOTOR CO.
16. Tighten the LH crossmember bolts.
    • Tighten to 70 Nm (52 lb-ft).
Fig 14: LH Side Crossmember Bolts
Courtesy of FORD MOTOR CO.
17. Tighten the RH crossmember bolts.
    • Tighten to 70 Nm (52 lb-ft).
Fig 15: RH Side Crossmember Bolts
Courtesy of FORD MOTOR CO.
18. Install the parking cable bracket.
    • Tighten to 55 Nm (41 lb-ft).
Fig 16: Parking Brake Cable Bracket Bolts
Courtesy of FORD MOTOR CO.
19. Lower the transmission onto the crossmember and install the rear transmission insulator nuts.
    • Tighten to 30 Nm (22 lb-ft).
Fig 17: Rear Transmission Insulator Nuts
Courtesy of FORD MOTOR CO.
20. Remove the high-lift transmission jack.
21. Install the fluid cooler tubes.
    • Tighten to 20 Nm (15 lb-ft).
Fig 18: Locating Fluid Cooler Tube(s)
Courtesy of FORD MOTOR CO.
22. Install the transmission fluid cooler tube bracket.
    • Tighten to 15 Nm (11 lb-ft).
Fig 19: Cooler Line Bracket
Courtesy of FORD MOTOR CO.
23. Connect the transmission harness connectors to the filler tube bracket.
Fig 20: Wire Harness Connectors
Courtesy of FORD MOTOR CO.
24. Install the ground wire.
    • Tighten to 23 Nm (17 lb-ft).
Fig 21: Ground Wire
Courtesy of FORD MOTOR CO.
25. Install the starter and the bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 22: Starter Bolts
Courtesy of FORD MOTOR CO.
26. Connect the electrical connectors on the starter.
    1. Tighten to 12 Nm (9 lb-ft).
    2. Tighten to 6 Nm (53 lb-in).
Fig 23: Starter Electrical Connectors
Courtesy of FORD MOTOR CO.
27. Install the starter motor electrical connector cap.
Fig 24: Starter Electrical Connector Cap
Courtesy of FORD MOTOR CO.
28. Install a new gasket and position the RH catalytic converter assembly in place. Loosely install the bolts. Do not tighten the bolts at this time.
Fig 25: RH Catalytic Converter Bolts
Courtesy of FORD MOTOR CO.
29. Install the RH exhaust flange nuts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 26: RH Exhaust Flange Bolts
Courtesy of FORD MOTOR CO.
30. Tighten the RH exhaust bolts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 27: RH Catalytic Converter Bolts
Courtesy of FORD MOTOR CO.
31. Connect the RH HO2S connector.
Fig 28: RH Heated Oxygen Sensor (HO2S) Sensor Connector
Courtesy of FORD MOTOR CO.
32. Connect the RH catalyst monitor connector.
Fig 29: RH Catalyst Monitor Connector
Courtesy of FORD MOTOR CO.
33. Install a new gasket and position the LH catalytic converter assembly in place. Loosely install the bolts. Do not tighten the bolts at this time.
Fig 30: LH Catalytic Converter Bolts
Courtesy of FORD MOTOR CO.
34. Install the LH exhaust flange nuts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 31: LH Exhaust Flange Bolts
Courtesy of FORD MOTOR CO.
35. Tighten the LH exhaust bolts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 32: LH Catalytic Converter Bolts
Courtesy of FORD MOTOR CO.
36. Connect the LH HO2S connector.
Fig 33: Identifying LH HO2S Connector
Courtesy of FORD MOTOR CO.
37. Connect the LH catalyst monitor connector.
Fig 34: LH Catalyst Monitor Connector
Courtesy of FORD MOTOR CO.
38. Install the selector lever cable bracket.
    • Tighten to 14 Nm (10 lb-ft).
Fig 35: Selector Lever Cable Bracket At Transmission
Courtesy of FORD MOTOR CO.
NOTE: The manual lever must be in the OVERDRIVE position.
39. Slide the transmission selector lever into the cable bracket until the tabs fully seat, and connect the selector lever cable at the manual lever.
    • Tighten to 30 Nm (22 lb-ft).
Fig 36: Selector Lever Cable At Transmission
Courtesy of FORD MOTOR CO.
NOTE: The output shaft and the driveshaft are a balanced assembly.
40. Install the driveshaft.
    • Align the paint marks and the index marks made during removal, position the driveshaft on the transmission.
Fig 37: Positioning Driveshaft On Transmission
Courtesy of FORD MOTOR CO.
NOTE: To maintain initial driveshaft balance, align the index marks made during removal.
41. Install the rear driveshaft.
    • Tighten to 103 Nm (76 lb-ft).
Fig 38: Identifying Driveshaft Bolts
Courtesy of FORD MOTOR CO.
42. Lower the vehicle.
43. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM article. Failure to follow these instructions may result in serious personal injury.
44. Fill the transmission with clean automatic transmission fluid and inspect for correct operation.