Servicing - A/t Ford Econoline E150

Transmission

Vehicles used in normal service do not require regularly scheduled maintenance. Fluid level should be checked whenever underhood maintenance is performed or if leakage is detected. Clutch bands on A4LD and C-6 should be adjusted when quality of shifts deteriorates or otherwise indicates improper band adjustment. On vehicles used for fleet service or those operated under severe conditions (such as police, taxi or towing), regular transmission fluid changes are required every 30,000 miles or when fluid appears discolored.

Transfer Case

Under normal driving conditions, replace transfer case fluid every 60,000 miles. Under severe driving conditions, perform this service more frequently.

1. Check fluid level with vehicle parked on level surface, engine and transmission at normal operating temperatures and engine idling. Apply parking brake and move transmission selector lever through all ranges, ending in "P".
2. Fluid level should be between "ADD" and "DON'T ADD" marks on dipstick (in crosshatched area). Add fluid through filler tube as needed. DO NOT overfill.

Remove fill plug. If fluid drains out or is level with opening, reinstall drain plug. If not, fill until fluid is level with fill plug opening.

RECOMMENDED FLUID

It is important that the proper lubricant be used. Motorcraft Mercon automatic transmission fluid WSP-M2C185-A should be used in both transmissions and transfer cases.

FLUID CAPACITY

Note. Fluid capacities listed are approximate. Always determine correct fluid level by mark on dipstick rather than by amount of fluid added.

TRANSMISSION REFILL CAPACITIES (1)

TRANSFER CASE REFILL CAPACITIES

1. Loosen oil pan bolts and tap pan to break gasket seal. Allow fluid to drain. Remove oil pan bolts and oil pan. Discard used filter and gasket. Install new filter and gasket. On all transmissions, clean pan and mounting surface. Install new gasket. CAUTION: On AOD transmissions, do not attempt to reuse oil filter after soaking filter in solvent. Filter material may disintegrate.
2. On all transmissions, add 3 quarts transmission fluid. Check fluid level as previously described. When filling a dry transmission and converter, refer to TRANSMISSION REFILL CAPACITIES. Recheck fluid level when transmission is at normal operating temperature. Do not overfill.

Remove drain plug from transfer case. Remove fill plug for easier draining. With fluid fully drained, reinstall drain plug. Fill transfer case to fill plug opening with Mercon ATF.

INTERMEDIATE (FRONT) OR OVERDRIVE BAND

1. Clean dirt from band adjusting screw area. Remove and discard band adjusting screw lock nut. Install new lock nut.
2. Tighten adjusting screw to 120 INCH lbs. (14 N.m). (Scheme 159) Back off screw exact number of turns. See INTERMEDIATE (FRONT) OR OVERDRIVE BAND ADJUSTMENT table. Hold adjusting screw in position and tighten new lock nut to 40 ft. lbs. (56 N.m).

INTERMEDIATE OR OVERDRIVE BAND ADJUSTMENT

Scheme 158

Scheme 159

A4LD Only

1. Clean all dirt from band adjusting screw area. Remove and discard band adjusting screw lock nut. Install new lock nut on adjusting screw.
2. Tighten screw to 120 INCH lbs. (14 N.m). Back off screw 2 full turns. Hold screw in position and tighten lock nut to 40 ft. lbs. (54 N.m).

Scheme 160

KICKDOWN CONTROL CABLE

Note. Kickdown control cable self-adjusts .5-1.5" (13-38 mm) after installation by depressing accelerator pedal to floor. No adjustment is required, but cable must be manually locked in adjusted position. Cable must be adjusted whenever removed or replaced.

AOD Only

1. T.V. control cable is set and locked to its proper length during initial assembly by pushing in locking tab at throttle body end of cable assembly. When tab is unlocked, cable is released for adjustment. Under normal circumstances, it should not be necessary to alter or readjust initial setting of T.V. control cable.
2. Set parking brake and put selector in "N". Do not put selector in "P". Remove cable linkage protective cover on vehicles with 4.9L and 5.0L engines. Ensure throttle lever is resting against idle stop. Do not adjust idle stop. Verify cable routing is free of sharp bends or pressure points and cable operates freely. Unlock locking tab at throttle body end by pushing up from below and prying up rest of way to free cable.
3. Install a retention spring with about 10 lbs. (4.5 kg) force to hold T.V. control lever to hold it in idle position (to rear of travel). Use 2 V8 throttle return springs to hold T.V. lever back, if necessary. Attach spring(s) to transmission T.V. lever and hook rear of spring to transmission case.
4. With T.V. cable locking tab unlocked and retention spring in place, rotate transmission outer T.V. lever 10-30 degrees and return slowly.
5. Push down locking tab until flush. Remove retention spring(s) from transmission lever.

VACUUM REGULATOR VALVE (VRV)

All models equipped with the 7.3L V8 diesel engine and automatic transmission include a VRV. Mounted on the left side of the fuel injection pump, it provides a vacuum signal to the transmission to control shift points. Signal strength is determined by a VRV.

Checking VRV Operation

1. Disconnect vacuum connector from VRV. Remove throttle cable from injection pump throttle lever (on right side of pump). Disconnect throttle return spring.
2. Attach one end of return spring over throttle lever ball stud. Install other end of spring over throttle cable support bracket. Insert .515" (13 mm) Gauge Block (T83T-7B200-AH) between pump boss and wide-open throttle stop screw. Spring will hold throttle lever against gauge block during vacuum check and VRV adjustment.
3. Attach vacuum pump to "VAC" (upper) port of VRV. Attach vacuum gauge to "TRANS" (lower) port. Apply and maintain 20 in. Hg vacuum. Vacuum gauge should indicate 6-8 in. Hg vacuum. If not, VRV requires adjustment.

Adjusting VRV

1. Loosen mounting screws (2) attaching VRV to fuel injection pump. With vacuum pump, gauge, gauge block and return spring in position (as during checking procedure), maintain 20 in. Hg vacuum with pump. Rotate VRV until vacuum gauge reads 7 in. Hg vacuum. Tighten mounting screws.
2. If correct vacuum reading cannot be obtained by adjusting VRV, it must be replaced. If correct reading is obtained, remove gauge block, and connect throttle return spring. Ensure pump lever returns to idle position.
3. Apply 20 in. Hg vacuum with vacuum pump and check gauge reading. If vacuum gauge reads less than 13 in. Hg, replace VRV. Remove vacuum pump and gauge and re-connect vacuum connector to VRV. Connect throttle cable.

GEARSHIFT LINKAGE

Note. Adjustment of manual shift linkage/cable is critical. Ensure "D" or (Overdrive) detent in transmission corresponds exactly with stop in console.

All Except Aerostar, Bronco II & Ranger

1. Move selector lever rearward against stop in "D" position. On models with column mounted shift levers, hold lever against stop by hanging an 8 lb. (3.6 kg) weight from selector lever.
2. Loosen manual lever-to-control cable (or rod) retaining nut. Move transmission manual lever to drive position (second detent from rear). Hold selector against rear of "D" position and tighten retaining nut. Check for normal operation in all selected positions.

Aerostar

1. From inside vehicle, place gearshift lever in "Overdrive" position. From under vehicle, loosen adjustment screw on shift cable and remove end fitting from manual lever ball stud.
2. Position manual lever in "Overdrive" position by moving lever all the way rearward, then moving it 3 detents forward. Connect cable end fitting to manual lever. NOTE: Excessive arm pressure can move shifter to "D" position. Apply pressure only until resistance of detent nib is felt.
3. Tighten adjusting screw to 45-60 INCH lbs. (5-7 N.m). After adjustment of shift linkage, check for "P" position engagement. Control lever must move to right when engaged in "P" detent.
4. Check control lever corresponds in all detent positions with engine running to ensure correct detent/transmission action.

Bronco II & Ranger

1. With engine off and parking brake applied, place shift lever in "D". Loosen trunnion bolt. Move shift lever at transmission all the way to the rear, then forward 4 steps. This places lever in "D" position.
2. Apply light forward pressure on shift control lever (at transmission) and tighten trunnion bolt to 18-31 ft. lbs. (13-23 N.m). Move lever through all positions making sure transmission is at full detent in each position.

NEUTRAL SAFETY SWITCH

Note. AOD and A4LD switches are not adjustable. If necessary, use Neutral Start Switch Socket (T74P-77247-A) to replace switch. If any other socket is used, damage to switch may occur.

Scheme 161

1. With transmission shift linkage properly adjusted, loosen the 2 switch attaching bolts. (Scheme 161)
2. Place transmission manual lever in neutral position. Rotate switch and insert a gauge pin (No. 43 drill bit) into gauge pin hole of switch.
3. Gauge pin must be inserted completely through all 3 holes of switch. Tighten switch attaching bolts and remove gauge pin. Check operation of switch. Engine should start in "N" or "P" positions, only.