APPLICATION
| Application | Transmission Model |
|---|---|
| Explorer & Mountaineer (2002) | 5R55W |
| Explorer & Mountaineer (2003) | 5R55S |
TRANSMISSION APPLICATION
| WARNING | Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION. |
| WARNING | On Pickup and Econoline equipped with electronic air suspension, power to air suspension system must be shut OFF prior to hoisting, jacking or towing an air suspension vehicle. The air suspension switch is located behind right kick panel area. Failure to do so can result in inflation or deflation of air springs, which may cause vehicle to shift during servicing. |
| WARNING | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. Before disconnecting battery, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION. |
| WARNING | Failure to secure the transmission to the transmission jack can result in personal injury. |
Scheme 32
Scheme 33
Scheme 34
Scheme 35
Scheme 36
Scheme 37
Scheme 38
Scheme 39
Scheme 40
Scheme 41
Scheme 42
Scheme 43
Scheme 44
Scheme 45
Scheme 46
Scheme 47
Scheme 48
Scheme 49
- Secure the transmission to the transmission jack with a safety chain.
- With the vehicle in Neutral, position it on a hoist.
- Disconnect the battery ground cable.
- Remove the radiator appearance cover. (Scheme 32)
- Remove the LH upper fan shroud bolt. (Scheme 33)
- If equipped, remove and discard the assembly screws.
- Remove the upper fan shroud bolts. (Scheme 34) Remove the RH bolt. If equipped, remove and discard the RH assembly screws. If equipped, disconnect the A/C line retainer. Remove the fan shroud.
- If equipped with a 4.0L engine, remove the exhaust manifold to Exhaust Gas Recirculation (EGR) valve tube.
- If equipped with a 4.0L engine, tap the hole in the RH cylinder head in order to install the lifting hook. (Scheme 35) Use a 10 x 1.50 mm (0.06 in) tap to tap the hole.
- If equipped with a 4.0L engine, install the lifting bracket in the previously tapped hole. (Scheme 36)
- If equipped with a 4.6L engine, remove the engine appearance cover. (Scheme 37)
- If equipped with a 4.6L engine, remove the battery ground cable and the bracket. (Scheme 38) Position the bracket and wire harness out of the way.
- If equipped with a 4.6L engine, install the Engine Lifting Bracket Set (303-D074). (Scheme 39)
- Install appropriate 3-bar engine support. (Scheme 40)
- Remove the drive shaft. See appropriate DRIVESHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
- If equipped, remove the 2 bolts on the bracket and position aside. (Scheme 41)
- Remove the components following the order indicated within the illustration. (Scheme 42)
- Install a suitable jack under the transmission.
- Remove the components following the order indicated within the illustrations. (Scheme 43)and (Scheme 44).
- Remove the 2 heat shield screws and position the heat shield aside to gain access to the oxygen sensor connectors.
- Remove the components following the order indicated within the illustrations. (Scheme 45)and (Scheme 46).
- Remove the 4 torque converter nuts. (Scheme 47)
- Remove the screw from the solenoid body connector and disconnect the connector. (Scheme 48)
- Hold the transmission case fittings with a wrench and disconnect the transmission cooler tubes. (Scheme 49)
- Position the bracket and fuel lines out of the way to gain access to the other transmission retaining screws.
- If equipped with a 4.6L engine, remove the front crossmember. (Scheme 50)
- If equipped with a 4.6L engine, remove the 7 engine-to-transmission retaining bolts. (Scheme 51)
- If equipped with a 4.0L engine, remove the 6 engine-to-transmission retaining bolts and position the fuel line bracket out of the way. (Scheme 52)
- Install the torque converter retainer tool.
- If equipped, remove transfer case. See appropriate REMOVAL & INSTALLATION article in TRANSFER CASES.
- If the transmission is to be overhauled or if installing a NEW or remanufactured transmission, carry out transmission backflushing and cleaning.
| WARNING | Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury. |
Scheme 50
Scheme 51
Scheme 52
Scheme 53
Scheme 54
Scheme 55
Scheme 56
- If equipped, install the transfer case. See appropriate REMOVAL & INSTALLATION article in TRANSFER CASES.
- Secure the transmission to the transmission jack with a safety chain.
- Install the components following the order within the illustrations. (Scheme 53)and (Scheme 54). Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-155936-S40571132202003063000000).
- Install the torque converter retention tool.
- Raise and position the transmission to the back of the engine. Remove the torque converter retention tool prior to attaching the transmission to the engine.
- On 4.6L models, install the engine-to-transmission retaining bolts. (Scheme 51) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-155936-S40571132202003063000000).
- On 4.0L models, position fuel line bracket in place and install 6 retaining bolts. (Scheme 52) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-155936-S40571132202003063000000).
- Install the front crossmembers. (Scheme 50)
- Position the fuel line bracket into place prior to installing the transmission retaining screws.
- Install the transmission fluid cooler tubes. (Scheme 49) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-155936-S40571132202003063000000).
- Use the following guidelines for the in-line transmission fluid filter: If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a NEW in-line fluid filter. If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter, install a NEW in-line fluid filter kit. If the transmission is being installed for a non-internal repair, DO NOT install an in-line filter or filter kit. If installing a NEW or a Ford authorized remanufactured transmission, install the in-line transmission fluid filter that is supplied. Prior to lowering the vehicle, install a NEW in-line transmission filter or a filter kit.
- Connect the LH Heated Oxygen Sensor (HO2S) to the transmission and install the wire harness. (Scheme 55)
- Connect the LH catalyst monitor connector to the transmission. (Scheme 56)
- Install and lubricate NEW "O" ring seals on the transmission connector and connect the connector. (Scheme 48) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-155936-S40571132202003063000000).
- Install a jackstand under the bell housing of the transmission.
- Remove the transmission jack.
- If equipped, install the cable bracket and the 2 bolts. (Scheme 41) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-155936-S40571132202003063000000).
- Position the catalytic converter assembly with the heat shield and loosely install the 4 converter-to-manifold nuts. see scheme 26 Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-155936-S40571132202003063000000).
- Install the components following the order within the illustrations. see scheme 27and see scheme 28. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-155936-S40571132202003063000000).
- Install the 2 RH heat shield bolts. see scheme 29 Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-155936-S40571132202003063000000).
- Loosely install the rear transmission support nuts. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-155936-S40571132202003063000000).
- Remove the jackstand from under the bell housing.
- Install the components following the order within the illustration. see scheme 30 Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-155936-S40571132202003063000000).
- Connect the fuel lines and the RH catalyst monitor connector to the bracket. see scheme 31 Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-155936-S40571132202003063000000).
- Install the drive shaft. See appropriate DRIVESHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
- Connect the battery ground cable. (Scheme 38)
- Carry out the fluid level check. For 2002 fluid level check, see «CHECKING FLUID LEVEL»(ref-141684-S14790324382002070100000) under LUBRICATION in SERVICING - EXPLORER & MOUNTAINEER article. For 2003 fluid level check, see «CHECKING FLUID LEVEL»(ref-155744-S42912613492003062400000) under LUBRICATION in SERVICING - EXPLORER & MOUNTAINEER article.
- Verify that the shift cable is correctly adjusted. For 2002 shift cable adjustment, see «SHIFT CABLE»(ref-141684-S18788899722002070100000) under ADJUSTMENTS in SERVICING - EXPLORER & MOUNTAINEER article. For 2003 shift cable adjustment, see «SHIFT CABLE»(ref-155744-S39169147052003062400000) under ADJUSTMENTS in SERVICING - EXPLORER & MOUNTAINEER article.
- Check the operation of the transmission and inspect for leaks.