Overhaul - E4OD: Removal & Installation Ford Bronco V

Removal

Raise and support vehicle. Index and remove rear drive shaft. Remove extension seal, using appropriate seal remover. Using appropriate bushing remover, remove extension housing bushing. Ensure extension housing is not scored.

Installation

1. Inspect extension housing bushing bore for burrs and remove burrs with an oil stone, as necessary. Install extension housing bushing, aligning lubrication slot to 6 o'clock position.
2. Install extension housing seal, aligning drain hole to 6 o'clock position. Ensure seal is seated against extension housing. Install drive shaft, aligning index marks.

Raise and support vehicle. Index and remove drive shaft(s). On 4WD vehicles, remove transfer case. See the appropriate TRANSMISSION REMOVAL & INSTALLATION - A/T article in this section. See the following menu. Remove transmission mount-to-transmission retaining bolts. Position transmission jack under transmission, and remove transmission mount-to-crossmember bolts. Remove 9 extension housing bolts. Remove extension housing and discard gasket.

1. 1993 models, see TRANSMISSION REMOVAL & INSTALLATION - A/T
2. 1994 models, see TRANSMISSION REMOVAL & INSTALLATION - A/T

Install NEW housing gasket and position extension housing on case. Ensure parking pawl spring is properly seated in case. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Remove extension housing. See EXTENSION HOUSING GASKET. Remove parking rod guide plate retaining bolts. Remove parking pawl return spring, pin and parking pawl from case. Remove Torx head bolt (40A) and parking pawl abutment. (Scheme 14)

For installation, reverse removal procedure. Ensure return spring end rests on inside surface of case, and parking rod guide plate dimple is facing inward. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Scheme 14

1. Remove solenoid body heat shield. Remove slotted heat shield. Remove solenoid body connector by pushing on center tab and pulling on wire harness. DO NOT attempt to pry tab with pry bar or screwdriver. Check electrical connectors for condition.
2. Loosen oil pan bolts and drain fluid. Remove oil pan, filter and "O" ring. DO NOT scratch or damage aluminum pump bore when removing "O" ring. Remove accumulator body. Remove main control body retaining bolts. DO NOT remove center 2 bolts. (Scheme 15) This keeps upper and lower valve body together during disassembly. Remove main control body.
3. Remove solenoid body Torx retaining bolts and one nut. Push down on solenoid body receptacle and remove solenoid body. Remove solenoid screen by rotating and pulling out. Remove reinforcing plate. Carefully lower separator plate and gasket so check balls, EPC ball and spring are retained.
4. Remove intermediate accumulator regulator filter and spring. (Scheme 16) Remove servo snap ring, retaining plate, servo piston and rod assembly, and servo spring.

Scheme 15

Scheme 16

1. Clean and inspect valve body thoroughly. DO NOT clean non-metallic check balls with solvent.
2. Install servo spring, servo piston and rod assembly. Install retaining plate and snap ring. (Scheme 17)
3. Lubricate valve body pockets with petroleum jelly. Place 9 check balls (rubber), Electronic Pressure Control (EPC) spring and EPC ball in position. (Scheme 18) Install separator plate and gaskets. Tighten bolts to specifications. See «TORQUE SPECIFICATIONS»(ref-25360-S29450496562001011700000). Stamped "UP" on reinforcing plate MUST be visible.
4. Install solenoid screen and lock in place. Install valve body over studs. Align manual valve with manual lever. Install and tighten retaining bolts to specification. Install accumulator body retaining bolts. Tighten to specification. Coat case connector bore with grease and install solenoid body retaining bolts and nut. Tighten to specification.
5. Install NEW filter and seal assembly. Install oil pan and NEW gasket. Check condition and placement of pan magnet. Tighten pan bolts to specification. Position solenoid body connector into receptacle. Audible click indicates full connection. Install solenoid body connector heat shield with offset bending inward.
6. Add transmission fluid and start engine. Fill transmission to proper level. Test vehicle for proper operation and ensure no leakage is present.

Scheme 17

Scheme 18

1. Remove manual lever position sensor connector. Remove shift cable from transmission manual lever, using a large screwdriver, pry control cable and fitting from lever ball and stud. Remove sensor retaining bolts.
2. Loosen oil pan bolts and drain transmission fluid. Remove oil pan, filter and "O" ring. Discard filter and "O" ring. DO NOT scratch or damage aluminum pump bore.
3. Using Lock Nut Pin Remover (T78P-3504-N), remove manual lever roll pin. (Scheme 19) Using a 21-mm box wrench, remove Inner detent lever nut. Hold lever with crescent wrench. Remove inner detent lever and park actuating rod assembly from manual lever. Remove manual lever and seal.

1. Clean seal bore opening with solvent. Using appropriate seal driver, install seal. Install manual lever, inner detent lever, park actuating rod assembly and NEW nut. Ensure inner detent lever is seated on flats of shaft, and rod assembly is through guide plate. Inner lever pin MUST BE aligned with manual valve.
2. Tighten inner detent lever nut to specification. See «TORQUE SPECIFICATIONS»(ref-25360-S29450496562001011700000) . Ensure manual valve detent spring is on inner detent lever and aligned with inner detent.
3. Install manual lever roll pin. Install manual lever position sensor finger tight. Use Gear Position Sensor Adjustor (T89T-70010-J) to align manual lever position sensor for Neutral gear position. Tighten bolts to specification. Install manual lever position sensor connector. Install shaft linkage and adjust. See the appropriate TRANSMISSION SERVICING article.
4. Install NEW filter and "O" ring assembly. Install oil pan and NEW gasket. Check condition and placement of pan magnet. Tighten oil pan retaining bolts to specifications. See «TORQUE SPECIFICATIONS»(ref-25360-S29450496562001011700000) .

Scheme 19

REMOVAL & INSTALLATION

See the appropriate TRANSMISSION REMOVAL & INSTALLATION - A/T article in this section.