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Home › Lincoln › 2005 › Aviator RWD › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transaxle/Transmission › Removal › Transmission - 4x2

Transmission - 4x2

SPECIAL TOOL(S) CHART

Tool Number Illustration Description
ST1636-A
G03863333Courtesy of FORD MOTOR CO.
 Retainer, Torque Converter 307-346 (T97T-7902-A)
    NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they can experience slightly different upshifts either (soft or firm) and that this is a temporary condition and will eventually return to normal operating condition.
  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the fan shroud bolts. Do not remove the fan shroud.
  3. Raise and support the vehicle. For additional information, refer to JACKING & LIFTING .
  4. If transmission disassembly or installation of a new transmission is necessary, drain the transmission fluid. Install the drain plug when finished.
  5. Remove the 2 RH heat shield bolts and position the shield aside.
    Fig 1: Removing 2 RH Heat Shield Bolts
    G03863334Courtesy of FORD MOTOR CO.
    6. NOTE: LH side shown, RH side similar.
    Fig 2: Disconnecting 2 Heated Oxygen Sensor Electrical Connectors
    G03863335Courtesy of FORD MOTOR CO.
  6. Disconnect the 2 heated oxygen sensor electrical connectors.
    7. NOTE: LH side shown, RH side similar.
    Fig 3: Disconnecting 2 Catalyst Monitor Sensor Electrical Connectors
    G03863336Courtesy of FORD MOTOR CO.
  7. Disconnect the 2 catalyst monitor sensor electrical connectors.
  8. Remove the RH heat shield bolts.
    Fig 4: Removing RH Heat Shield Bolts
    G03863337Courtesy of FORD MOTOR CO.
  9. Remove the RH heat shield bolt and remove the heat shield.
    Fig 5: Removing RH Heat Shield Bolt
    G03863338Courtesy of FORD MOTOR CO.
  10. Remove the LH heat shield bolt.
    Fig 6: Removing LH Heat Shield Bolt
    G03863339Courtesy of FORD MOTOR CO.
  11. Remove the 2 nuts and the plastic shield on the right side of the crossmember near the fuel tank.
    Fig 7: Removing Nuts
    G03863340Courtesy of FORD MOTOR CO.
    12. NOTE: RH side shown, LH side similar.
    Fig 8: Removing Upper Crossmember Bolts
    G03863341Courtesy of FORD MOTOR CO.
  12. Remove the 4 upper crossmember bolts (2 on each side).
  13. Remove the bolts, springs, flag nuts and separate the muffler from the converter.
    • Discard the gasket.
    • Discard the flag nuts.
    Fig 9: Discarding Flag Nuts
    G03863342Courtesy of FORD MOTOR CO.
    14. NOTE: LH side shown, RH side similar.
    Fig 10: Removing 4 Converter-To-Manifold Nuts
    G03863343Courtesy of FORD MOTOR CO.
  14. Remove the 4 converter-to-manifold nuts. Remove the jackstand and lower the converter assembly with the heat shield.
    15. WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.
  15. Install a suitable jack under the transmission.
  16. Remove the RH side crossmember bolts.
    Fig 11: Removing RH Side Crossmember Bolts
    G03863344Courtesy of FORD MOTOR CO.
  17. Remove the LH side crossmember bolts.
    Fig 12: Removing LH Side Crossmember Bolts
    G03863345Courtesy of FORD MOTOR CO.
  18. Remove the 2 bolts on the bracket and position aside.
    Fig 13: Removing Bolts On Bracket
    G03863346Courtesy of FORD MOTOR CO.
  19. Remove the transmission support insulator nuts and remove the crossmember.
    Fig 14: Removing Transmission Support Insulator Nuts
    G03863347Courtesy of FORD MOTOR CO.
    20. NOTE: This step may require an assistant.
    Fig 15: Removing Bolt Of 3-Way Converter System
    G03863348Courtesy of FORD MOTOR CO.
  20. Remove the transmission mounted exhaust hanger and the 3-way converter assembly.
    1. Remove the bolt and 3-way system.
    2. If required, remove the other bolt and the mount.
  21. Remove the shift cable and bracket and position out of PARK.
    1. Disconnect the cable from the lever.
    2. Position the manual lever out of PARK.
    3. Remove the bolts and the shift cable and bracket and position aside.
    Fig 16: Disconnecting Cable From Lever
    G03863349Courtesy of FORD MOTOR CO.
  22. Remove the rear driveshaft pinion flange bolts.
    1. Index-mark the location of the rear flange and pinion flange.
    2. Remove the 4 bolts.
    Fig 17: Removing Bolts
    G03863350Courtesy of FORD MOTOR CO.
    23. NOTE: Do not use a hammer.
    Fig 18: Removing Driveshaft Flange From Pinion Flange
    G03863351Courtesy of FORD MOTOR CO.
  23. Remove the driveshaft flange from the pinion flange, using a pry bar.
  24. Index-mark the driveshaft and the extension housing. Remove the driveshaft from the vehicle.
    Fig 19: Removing Driveshaft From Vehicle
    G03863352Courtesy of FORD MOTOR CO.
  25. Remove the electrical connector cover.
    Fig 20: Removing Electrical Connector Cover
    G03863353Courtesy of FORD MOTOR CO.
  26. Remove the starter wire and positive battery cable.
    Fig 21: Removing Starter Wire
    G03863354Courtesy of FORD MOTOR CO.
  27. Remove the starter motor bolts and starter.
    Fig 22: Removing Starter Motor Bolts
    G03863355Courtesy of FORD MOTOR CO.
  28. Remove the flexplate cover.
    Fig 23: Removing Flexplate Cover
    G03863356Courtesy of FORD MOTOR CO.
  29. Remove the access cover.
    Fig 24: Removing Access Cover
    G03863357Courtesy of FORD MOTOR CO.
    30. NOTE: Make an identifying mark on the nut, stud and flexplate to allow for correct installation.
    Fig 25: Removing Torque Converter Nuts
    G03863358Courtesy of FORD MOTOR CO.
  30. Remove the 4 torque converter nuts.
  31. Lower the transmission to gain access to the sensor connectors and the transmission bolts.
  32. Disconnect the RH catalyst monitor connector and the fuel lines from the bracket.
    Fig 26: Disconnecting RH Catalyst Monitor Connector
    G03863359Courtesy of FORD MOTOR CO.
  33. Disconnect the RH heated oxygen sensor from the transmission.
    Fig 27: Disconnecting RH Heated Oxygen Sensor From Transmission
    G03863360Courtesy of FORD MOTOR CO.
  34. Disconnect the LH heated oxygen sensor and the harness clip from the transmission.
    Fig 28: Disconnecting LH Heated Oxygen Sensor
    G03863361Courtesy of FORD MOTOR CO.
  35. Disconnect the LH catalyst monitor connector from the transmission.
    Fig 29: Disconnecting LH Catalyst Monitor Connector From Transmission
    G03863362Courtesy of FORD MOTOR CO.
  36. Move the rubber boot back to gain access to the connector.
    Fig 30: Moving Rubber Boot Back To Gain Access To Connector
    G03863363Courtesy of FORD MOTOR CO.
  37. Disconnect the digital transmission range (TR) sensor connector.
    Fig 31: Disconnecting Digital Transmission Range (TR) Sensor Connector
    G03863364Courtesy of FORD MOTOR CO.
  38. Disconnect the turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor and intermediate shaft speed (ISS) sensor electrical connectors.
    Fig 32: Disconnecting Turbine Shaft Speed (TSS) Sensor, Output Shaft Speed (OSS) Sensor
    G03863365Courtesy of FORD MOTOR CO.
    39. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector.
    Fig 33: Disconnecting Connector
    G03863366Courtesy of FORD MOTOR CO.
  39. Remove the screw from the solenoid body connector and disconnect the connector.
  40. Disconnect the harness retainers.
    Fig 34: Disconnecting Harness Retainers
    G03863367Courtesy of FORD MOTOR CO.
    41. CAUTION: Do not damage the cooler tubes.
    Fig 35: Disconnecting Transmission Cooler Tubes
    G03863368Courtesy of FORD MOTOR CO.
  41. Disconnect the transmission cooler tubes.
  42. Remove the front crossmember.
    Fig 36: Removing Front Crossmember
    G03863369Courtesy of FORD MOTOR CO.
  43. Remove the 7 engine-to-transmission retaining bolts.
    Fig 37: Removing Engine-To-Transmission Retaining Bolts
    G03863370Courtesy of FORD MOTOR CO.
  44. Lower the transmission assembly from the vehicle.
  45. Install the special tool.
    Fig 38: Installing Special Tool
    G03863371Courtesy of FORD MOTOR CO.
  46. 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 - BACKFLUSHING AND CLEANING .
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