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Section 1366 (Automatic Transmission): Removal: Transmission

WARNING: This page is about a different car, the 2005 Lincoln Town Car. However, it is still accessible from the selected car via links, so may be relevant.
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 .

  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
    3. NOTE: Do not drain the transmission unless disassembly or installation of a new transmission is required.
    Fig 1: Locating Transmission Fluid Pan Bolts
    G04584256Courtesy of FORD MOTOR CO.
  3. 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.
  4. 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 Transmission Fluid Pan
    G03882578Courtesy of FORD MOTOR CO.
  5. Remove the drain pan.
    6. 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
    G04016647Courtesy of FORD MOTOR CO.
  6. Mark the rear driveshaft yoke and the axle pinion flange and remove the 4 bolts.
  7. Index-mark the driveshaft and extension housing. Separate the driveshaft from the transmission.
    Fig 4: Separating Driveshaft From Transmission
    G03963933Courtesy of FORD MOTOR CO.
  8. Remove the torque converter access cover plug at the left rear engine block.
    Fig 5: Identifying Rubber Access Plug
    G04584454Courtesy of FORD MOTOR CO.
  9. Remove the torque converter access cover.
    1. Remove the bolts.
    2. Remove the bolt.
    3. Remove the inspection cover.
    Fig 6: Removing Torque Converter Access Cover
    G04016789Courtesy of FORD MOTOR CO.
    10. 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
    G04584761Courtesy of FORD MOTOR CO.
  10. Remove and discard the 4 torque converter-to-flexplate nuts.
  11. Disconnect the RH HO2S sensor connector.
    Fig 8: Disconnecting RH HO2S Sensor Connector
    G04016753Courtesy of FORD MOTOR CO.
  12. Disconnect the RH catalyst monitor connector.
    Fig 9: Disconnecting RH Catalyst Monitor Connector
    G04016678Courtesy of FORD MOTOR CO.
  13. Remove the bolts from the RH exhaust flange.
    Fig 10: Removing Bolts From RH Exhaust Flange
    G04016652Courtesy of FORD MOTOR CO.
  14. Loosen the exhaust clamp and remove the RH exhaust pipe.
    Fig 11: Loosening Exhaust Clamp And Removing RH Exhaust Pipe
    G04016653Courtesy of FORD MOTOR CO.
  15. Disconnect the LH HO2S sensor connector.
    Fig 12: Disconnecting LH HO2S Sensor Connector
    G04584303Courtesy of FORD MOTOR CO.
  16. Disconnect the LH catalyst monitor connector.
    Fig 13: Disconnecting LH Catalyst Monitor Connector
    G04584304Courtesy of FORD MOTOR CO.
  17. Remove the bolts from the LH exhaust flange.
    Fig 14: Removing Bolts From LH Exhaust Flange
    G04016656Courtesy of FORD MOTOR CO.
  18. Loosen the exhaust clamp and remove the LH exhaust pipe.
    Fig 15: Loosening Exhaust Clamp And Removing LH Exhaust Pipe
    G03882571Courtesy of FORD MOTOR CO.
    19. NOTE: Make a reference mark on the shift cable linkage to the transmission.
    Fig 16: Disconnecting Transmission Shift Linkage
    G04016717Courtesy of FORD MOTOR CO.
  19. Disconnect the transmission shift linkage.
  20. Remove the shift cable bracket and position aside.
    Fig 17: Removing Shift Cable Bracket
    G04016800Courtesy of FORD MOTOR CO.
  21. Remove the ground wire.
    Fig 18: Removing Ground Wire
    G04016801Courtesy of FORD MOTOR CO.
  22. Remove the starter electrical connector cap.
    Fig 19: Removing Starter Electrical Connector Cap
    G04016802Courtesy of FORD MOTOR CO.
  23. Disconnect the electrical connectors.
    Fig 20: Disconnecting Electrical Connectors
    G03882596Courtesy of FORD MOTOR CO.
  24. Remove the 3 starter bolts and the starter.
    Fig 21: Removing Starter Bolts
    G04016804Courtesy of FORD MOTOR CO.
    25. NOTE: The case connectors must be held in place to prevent them from moving.
    Fig 22: Disconnecting Transmission Fluid Cooler Tubes
    G03888672Courtesy of FORD MOTOR CO.
  25. Disconnect the transmission fluid cooler tubes.
  26. Remove the cooler line bracket and position aside.
    Fig 23: Removing Cooler Line Bracket And Position Aside
    G04016806Courtesy of FORD MOTOR CO.
  27. Position a suitable jack under the transmission. Secure the transmission to the jack with safety straps.
  28. Remove the rear transmission insulator nuts.
    Fig 24: Removing Rear Transmission Insulator Nuts
    G03882600Courtesy of FORD MOTOR CO.
  29. Remove the RH side crossmember bolts.
    Fig 25: Removing RH Side Crossmember Bolts
    G04016658Courtesy of FORD MOTOR CO.
  30. Remove the LH side crossmember bolts.
    Fig 26: Removing LH Side Crossmember Bolts
    G04016763Courtesy of FORD MOTOR CO.
  31. Remove the bolts and remove the parking cable bracket and position aside.
    Fig 27: Removing Parking Cable Bracket
    G04016660Courtesy of FORD MOTOR CO.
    32. 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: Lowering RH Side Of Crossmember
    G04016661Courtesy of FORD MOTOR CO.
  32. Lower the RH side of the crossmember.
    33. 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: Lowering LH Side Of Crossmember And Removing Crossmember
    G04016766Courtesy of FORD MOTOR CO.
  33. Lower the LH side of the crossmember and remove the crossmember.
  34. Remove the rear transmission insulator.
    Fig 30: Removing Rear Transmission Insulator Nuts
    G04002168Courtesy of FORD MOTOR CO.
    35. 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 Removing From Filler Tube
    G03882607Courtesy of FORD MOTOR CO.
  35. Disconnect the wire harness connectors and remove them from the filler tube.
  36. Remove the bolt.
    Fig 32: Removing Bolt
    G04016631Courtesy of FORD MOTOR CO.
  37. Position the fluid filler tube aside.
    Fig 33: Positioning Fluid Filler Tube
    G04016632Courtesy of FORD MOTOR CO.
  38. Remove the transmission retaining bolts.
    Fig 34: Removing Transmission Retaining Bolts
    G04016817Courtesy of FORD MOTOR CO.
  39. Separate and lower the transmission from the engine. Partially lower the transmission from under the vehicle.
  40. 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 Catalyst Monitor Connector Retainer & Transmission Solenoid Body Electrical Connector
    G04016818Courtesy of FORD MOTOR CO.
  41. 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
    G03882612Courtesy of FORD MOTOR CO.
  42. Lower the transmission from under the vehicle.
  43. 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 .
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