Automatic Transmission & Transfer Case Removal & Installation Ford Econoline I

Note. Unless otherwise specified, references to Pickup include the F350 Super Duty commercial chassis.

MANUAL TRANSMISSION

Note. For manual transmission removal and installation procedures, see appropriate article in CLUTCHES.

Removal (Windstar)

1. Disconnect negative and positive battery cables. Remove battery and battery tray. Remove air cleaner assembly. Disconnect necessary electrical connections. Disconnect shift cable from transaxle. Remove vehicle hood. Remove wiper arm and pivot assembly. Remove upper radiator shield.
2. Disconnect oil cooler lines from transaxle and plug openings. Remove upper transaxle-to-engine bolts. Disconnect wiring harness bracket from transaxle. Install appropriate brackets and Three-Bar Engine Support (014-00750) and Adapter Kit (014-00792). Remove upper fluid filler tube.
3. Raise and support vehicle. Drain transmission fluid. Remove front wheels. Remove axle shafts. See appropriate FWD AXLE SHAFTS article in DRIVE AXLES. Disconnect oxygen sensor. Remove 3-way catalytic converter assembly. Remove ground strap. Disconnect steering shaft from steering gear.
4. Disconnect power steering hoses from steering gear. Disconnect front stabilizer links from stabilizer bar. Disconnect tie rods and ball joints from steering knuckles. Remove engine mount-to-subframe nuts.
5. Support subframe with Hi-Lift Jack (014-00210) and Subframe Removal Kit (014-00751). Remove subframe-to-body bolts. Remove subframe with steering gear, stabilizer bar, lower strut arm and lower control arms attached.
6. Disconnect speedometer cable. Remove starter. Remove flexplate inspection cover. Remove flexplate-to-torque converter nuts. Disconnect any remaining sensor connectors. Support transaxle with transmission jack. Remove remaining transaxle-to-engine bolts. Remove transaxle from vehicle.

Installation (Windstar)

1. Reverse removal procedure to install. Ensure torque converter is fully seated. Align reference marks on axle shafts.
2. Tighten all bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-transfer-case-removal-installation) . Fill transaxle with Motorcraft Mercon ATF (XT-2-QDX). For fluid capacity and control cable or linkage adjustment, see appropriate AUTOMATIC TRANSMISSION servicing article.

Scheme 1

1. Disconnect negative battery cable. Remove dipstick. Place transmission in Neutral. Raise and support vehicle. Remove skid plate (if equipped). Mark drive shaft and axle flange or yoke for reassembly reference. Remove drive shaft(s).
2. On F350 Super Duty commercial chassis, disconnect speedometer cable from parking brake assembly. (Scheme 1) Loosen lock nut on parking brake cable at clevis. Remove clevis pin, clevis, and lock nut from parking brake cable. Remove parking brake cable from bracket on parking brake assembly.
3. On all models, disconnect control cables, shift linkage, and speedometer cable from transmission. On 4WD models, remove shift linkage from transfer case (manual shift models), or unplug connector at transfer case (models with electronic shift). Unplug 4WD switch connector from transfer case. Detach wiring harness from retainers on frame rail.
4. On all models, remove necessary heat shields for access to electrical connectors. Unplug connector from Manual Lever Position Sensor (MLPS), mounted at shift lever on transmission. Unplug connector from solenoid assembly on side of transmission. CAUTION: Remove electrical connector from MLPS by squeezing tabs together and pulling connector from MLPS. Remove electrical connector from solenoid assembly by pushing inward on center tab. DO NOT pry on tab(s) with screwdriver.
5. Loosen oil pan bolts to allow fluid to drain. When fluid stops draining, remove all but 2 bolts at front of oil pan. Allow oil pan to drop. Drain remaining fluid. Reinstall bolts to hold oil pan in place.
6. Remove torque converter cover. Remove starter motor. Remove torque converter-to-drive plate nuts. Support transmission with floor jack. Remove transmission mount-to-crossmember nuts and crossmember-to-frame bolts.
7. Remove crossmember. Disconnect oil cooler lines and filler tube from transmission. Plug all oil cooler line openings. Secure transmission to floor jack with safety chain. Remove transmission-to-cylinder block bolts. Move transmission rearward and lower from vehicle.
8. On F350 Super Duty commercial chassis, remove parking brake assembly, remove retaining bolts, parking brake assembly, and gasket if necessary. (Scheme 1)

Installation (Expedition, Navigator, Pickup & Van)

1. Reverse removal procedure to install. Use NEW "O" ring on filler tube. Ensure torque converter is fully seated. Align reference marks on drive shaft and axle flange or yoke.
2. On F350 Super Duty commercial chassis, use NEW gasket and retaining bolts when installing parking brake assembly. DO NOT reuse bolts. On all models, tighten all bolts/nuts to specification. See appropriate TORQUE SPECIFICATIONS table. CAUTION: Pickup F350 Super Duty commercial chassis parking brake assembly contains a separate reservoir from transmission. Check lubricant level at filler plug hole on side of parking brake assembly. Fluid level should be even with bottom of filler plug hole. Add Motorcraft Mercon ATF (XT-2-QDX) as needed.
3. Fill transmission with Motorcraft Mercon ATF (XT-2-QDX). For fluid capacity and control cable or linkage adjustment, see appropriate AUTOMATIC TRANSMISSION servicing article.

Removal (Villager)

1. Disconnect negative battery cable. Remove axle shafts. Remove starter motor. Disconnect Transmission Range (TR) switch electrical connector. Disconnect 2 electrical connectors mounted on electrical connector mounting brackets. Remove electrical connector mounting brackets.
2. Disconnect crankshaft position sensor electrical connector and remove sensor. Remove oil filler tube. Remove upper transaxle mounting bolts. Raise and support vehicle. Remove left inner splash shield. See appropriate FWD AXLE SHAFTS article in DRIVE AXLES.
3. Drain transmission fluid. Remove exhaust pipe bracket. Remove front and rear transaxle-to-engine brace. Remove flexplate inspection cover. Disconnect shift cable from transmission bracket and TR switch.
4. Disconnect necessary electrical and ground connections. Remove vehicle speed sensor. Disconnect breather tube. Remove flexplate-to-torque converter bolts. Disconnect oil cooler lines from transaxle and plug all openings.
5. Support transaxle with transmission jack. Remove transaxle-to-engine bolts. Remove front and rear transaxle mounts. Remove transaxle from vehicle.

Installation (Villager)

1. Reverse removal procedure to install. Ensure torque converter is fully seated. Converter bolt mounting surface should be .76" (19 mm) below bell housing mounting surface prior to installation if converter is installed correctly. Align reference marks on axle shafts.
2. Tighten all bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-transfer-case-removal-installation) . Fill transaxle with Motorcraft Mercon ATF (XT-2-QDX). For fluid capacity and control cable or linkage adjustment, see appropriate AUTOMATIC TRANSMISSION servicing article.

Removal (Explorer, Mountaineer & Ranger)

1. Ensure selector lever is in Neutral. Disconnect negative battery cable. Remove transmission dipstick. Raise and support vehicle. Drain transmission.
2. Remove torque converter access cover (if equipped). Remove starter. Mark torque converter and flexplate alignment for installation reference. Remove and discard torque converter nuts.
3. Mark drive shaft and companion flange alignment for installation reference. Remove drive shaft. Disconnect shift cable from transmission. Disconnect electrical harness and sensor connectors. Remove catalytic converter. Disconnect oil cooler lines at transmission and plug all openings.
4. Remove engine mount-to-crossmember nuts. Support transmission with transmission jack. Remove crossmember. Remove transmission mount.
5. On 4WD models, remove transfer case and transmission vent tube. See appropriate transfer case removal under «TRANSFER CASE (A/T)»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-transfer-case-removal-installation__transfer-case-at) . On all models, remove oil filler tube. Position wiring harness and hardware aside. Remove transmission-to-engine retaining bolts. Remove transmission.

Installation (Explorer, Mountaineer & Ranger)

1. To install, reverse removal procedure. Use NEW "O" ring on filler tube. Ensure torque converter is fully seated. Align reference marks on drive shaft and axle flange or yoke.
2. Tighten torque converter drain plug and all bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-transfer-case-removal-installation) . Fill transmission with Motorcraft Mercon ATF (XT-2-QDX). For fluid capacity and control cable or linkage adjustment, see appropriate AUTOMATIC TRANSMISSION servicing article.

Removal (Expedition & Navigator)

1. Ensure selector lever is in Neutral. Raise vehicle and drain transmission fluid. Remove filler tube and disconnect cooler lines. Remove transfer case from 4WD models. Mark drive shaft flanges and yokes for reassembly reference.
2. Remove rear driveshaft. Disconnect shift cable and housing. Disconnect electrical harness and sensor connectors from transmission. Remove starter motor. Remove cover/plug from cylinder block to access converter nuts. Remove and discard converter nuts. Remove flywheel inspection cover.
3. Install transmission support jack under transmission. Ensure supports and straps DO NOT contact Cooler By-pass Valve (CBV). Remove exhaust system as necessary. Remove crossmember assembly.
4. Remove transmission-to-engine mounting bolts. Ensure ground strap is disconnected. Move transmission to rear and install converter holding bracket. Lower transmission unit from vehicle.

Installation (Expedition & Navigator)

1. To install, reverse removal procedure. Use NEW "O" ring on filler tube. Ensure torque converter is fully seated in transmission. Lubricate converter hub pilot hub. Align reference marks on drive shaft and axle flange or yoke.
2. Tighten torque converter drain plug and all bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-transfer-case-removal-installation) . Ensure all electrical connectors and ground strap are connected.
3. Fill transmission with Motorcraft Mercon ATF (XT-2-QDX). For fluid capacity and control cable or linkage adjustment, see appropriate AUTOMATIC TRANSMISSION servicing article.

Removal (Explorer & Mountaineer)

1. Disconnect negative battery cable. Place gear selector in NEUTRAL position. Raise and support vehicle. Drain transmission fluid. On 4WD models, remove transfer case. See appropriate procedure under «TRANSFER CASE (A/T)»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-transfer-case-removal-installation__transfer-case-at) .
2. Mark rear drive shaft yoke and companion flange for reassembly reference. Disconnect drive shaft from companion flange. Slide drive shaft to rear to separate from transmission.
3. Remove flexplate inspection cover. Remove torque converter nuts. Disconnect shift cable from transmission. Disconnect oil cooler lines at transmission and plug all openings. Disconnect necessary electrical connections.
4. Support transmission with transmission jack. Remove crossmember. Remove transmission mount. Remove 3-way catalytic converters. Remove transmission-to-engine bolts. Remove transmission filler tube. Remove transmission from vehicle.

Installation (Explorer & Mountaineer)

1. Lubricate torque converter pilot with chassis grease. Install torque converter into transmission. Rotate torque converter to engage drive flats with pump gear.
2. Raise transmission into position. Torque converter will move freely with respect to flywheel when it is properly positioned. Install and tighten transmission housing bolts. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-transfer-case-removal-installation) .
3. Reverse removal procedure to complete installation. Use NEW "O" ring on filler tube. Lubricate drive shaft yoke splines with grease. Align reference marks on drive shaft and axle flange.
4. Fill transmission with Motorcraft Mercon ATF (XT-2-QDX). For fluid capacity and control cable adjustment, see appropriate AUTOMATIC TRANSMISSION servicing article.

Removal (Pickup & Van)

1. Disconnect negative battery cable. If vehicle is equipped with 2 batteries, disconnect all positive and negative cables. Remove air cleaner and duct. Remove dipstick. On Van, remove engine cover. Raise and support vehicle. Drain transmission fluid. Remove fluid fill tube. Remove converter drain plug access cover or flywheel inspection cover. Remove converter nuts. Drain torque converter.
2. Mark rear drive shaft yoke and companion flange for reassembly reference. Disconnect drive shaft from companion flange. Slide drive shaft to rear to separate from transmission. Install plug into extension housing to prevent leaks.
3. Remove starter. Disconnect electrical harness and sensor connectors. Disconnect shift cable from selector lever. Remove rear mount bolts and crossmember bolts. Remove rear support bolts. Raise transmission enough to remove rear mount from crossmember. Remove crossmember.
4. Lower transmission enough to disconnect oil cooler lines (if not previously disconnected). Plug oil cooler line openings. Secure transmission to jack. Remove converter housing bolts. Carefully move transmission to rear and downward to remove it from vehicle.

Installation (Pickup & Van)

1. Lubricate torque converter pilot with chassis grease. Install torque converter into transmission. Rotate torque converter to engage drive flats with pump gear.
2. Raise transmission into position. Torque converter studs must align with holes in flywheel/flex plate. Ensure flywheel is correctly aligned and does not bind. Install and tighten transmission housing bolts. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-transfer-case-removal-installation) .
3. Reverse removal procedure to complete installation. Use NEW "O" ring on filler tube. Lubricate drive shaft yoke splines with grease. Align reference marks on drive shaft and axle flange.
4. Fill transmission with Motorcraft Mercon ATF (XT-2-QDX). For fluid capacity, see appropriate AUTOMATIC TRANSMISSION servicing article.

TRANSFER CASE (A/T)

Removal (Expedition, Explorer, Mountaineer, Navigator & Ranger)

1. Raise and support vehicle. Remove skid plate (if equipped). Remove damper from transfer case (if equipped). Drain fluid from transfer case. Install drain plug. Disconnect electrical connectors as necessary and position aside.
2. Mark drive shaft and axle flange or yoke for reassembly reference. Remove drive shafts from transfer case and secure out of the way. Remove exhaust heat shields as necessary.
3. Disconnect speedometer drive or sensor. Disconnect vent hose. On models with manual shift lever, remove shift lever.
4. Remove shift lever assembly and bushing from transmission extension housing. On all models, support transfer case with jack. Remove transfer case-to-extension housing retaining bolts.
5. Slide transfer case rearward from transmission output shaft and lower from vehicle. Remove gasket from transfer case and transmission extension housing.

Scheme 2

Scheme 3

1. To install transfer case, reverse removal procedure. Use NEW gasket between transfer case and transmission extension housing. It may be necessary to use grease to hold gasket in place. Tighten transfer case bolts to specification in sequence. (Scheme 2) See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-transfer-case-removal-installation).
2. On models with manual shift lever, install shift lever assembly with retaining bolts loosely installed. Raise manual shift lever boot for access to cam plate. (Scheme 3)
3. Set shift lever to 4L position. Rotate cam plate around bolt "A" clockwise until bottom chamfered corner of neutral lug contacts forward right edge of manual shift lever at point "C". (Scheme 3)
4. Hold cam plate in this position. Tighten bolt "A" to 70-90 ft. lbs. (95-122 N.m), and then bolt "B" to 31-42 ft. lbs. (42-57 N.m). Move manual shift lever into all gear positions and check for proper engagement.
5. Ensure clearance exists between manual shift lever and cam plate in 2H and 4H positions, and no more than.13" (3.3 mm) clearance exists when in 4L position. (Scheme 3) Install manual shift lever boot.
6. On all models, install speedometer drive gear. Install drive shafts. Align reference marks. Install vent hose with White reference mark aligned with notch on mounting bracket (models with electronic shift), or notch on manual shift lever (models with manual shift lever).
7. Tighten drain plug to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-transfer-case-removal-installation). Fill transfer case to bottom of filler plug hole with Motorcraft Mercon ATF (XT-2-QDX). Install filler plug, and tighten to specification. To install remaining components, reverse removal procedure.

Removal (Pickup)

1. Raise and support vehicle. Remove skid plate (if equipped). Drain fluid from transfer case. Install drain plug. Unplug necessary electrical connections at transfer case.
2. Mark drive shaft and axle flange or yoke for reassembly reference. Remove drive shafts from transfer case and secure out of the way. Disconnect vent hose. On models with manual shift lever, disconnect shift rod between transfer case shift lever and manual shift control lever assembly. On all models, support transfer case with jack.
3. Remove transfer case retaining bolts. Slide transfer case rearward from transmission output shaft. Lower transfer case from vehicle to remove. Remove gasket.

Installation (Pickup)

1. To install, reverse removal procedure. Use NEW gasket between transfer case and transmission extension housing. It may be necessary to use grease to hold gasket in place.
2. Tighten transfer case bolts to specification in sequence. (Scheme 4) See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-transfer-case-removal-installation).
3. When installing drive shafts, align reference marks. Tighten drain plug to specification.
4. Fill transfer case to bottom of filler plug hole with Motorcraft Mercon ATF (XT-2-QDX). Install filler plug. Tighten to specification. To install remaining components, reverse removal procedure.

Scheme 4

Removal (Expedition, Navigator & Pickup)

1. Raise and support vehicle. Drain transfer case. Mark drive shaft and axle flange or yoke for reassembly reference. Remove drive shafts from transfer case and secure out of the way.
2. Remove torsion bars and rear torsion bar support. Remove skid plate. On manual shift model, disconnect shift rod using Shift Linkage Insulator (T67P-7341-A).
3. On all models, disconnect necessary electrical connections at transfer case. Support transfer case. Remove transfer case retaining bolts. Remove transfer case.

Installation (Expedition, Navigator & Pickup)

1. To install, reverse removal procedure. Use NEW gasket between transfer case and transmission extension housing. It may be necessary to use grease to hold gasket in place.
2. Tighten transfer case bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/automatic-trans/#automatic-transmission-transfer-case-removal-installation) . When installing drive shafts, align reference marks. Tighten drain plug to specification.
3. Fill transfer case to bottom of filler plug hole with Motorcraft Mercon ATF (XT-2-QDX). Install filler plug. Tighten to specification. To install remaining components, reverse removal procedure.

TORQUE SPECIFICATIONS (TRANSFER CASE)

Note. For drive shaft nut and bolt torque specifications, refer to TORQUE SPECIFICATIONS .

Note. For additional Transfer Case torque specifications, see appropriate OVERHAUL article.

TORQUE SPECIFICATIONS (TRANSFER CASE)

TORQUE SPECIFICATIONS (TRANSMISSION)

Note. For drive shaft nut and bolt torque specifications, refer to TORQUE SPECIFICATIONS .

TORQUE SPECIFICATIONS (TRANSMISSION)

See also:
• TORQUE SPECIFICATIONS
• TORQUE SPECIFICATIONS
• TRANSFER CASE (A/T)