Automatic Transmission: Removal & Installation Ford Explorer III

Removal And Installation

Note. Make sure that the fluid filter seals are correctly seated on the filter.

Note. The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.

Note. Install a new transmission fluid filter.

Scheme 253

1. With the vehicle in PARK, position on a hoist.
2. Remove the components in the order indicated in the following illustration and table.
3. To install, reverse the removal procedure.
4. Partially fill the transmission. For additional information, refer to «TRANSMISSION FLUID DRAIN AND REFILL - WITHOUT TORQUE CONVERTER DRAIN PLUG»(ref-194049-S42751872242005092600000) .

Item 6: Transmission Fluid Pan Filter Installation Note

1. Lubricate the seals and install the transmission fluid filter.

Scheme 254

1. Install the transmission fluid pan and gasket and loosely install the screws.

Scheme 255

1. Tighten the screws in a crisscross sequence.

Scheme 256

Scheme 257

Note. Make sure that the fluid filter seals are correctly seated on the filter.

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 may experience slightly different upshifts (either soft or firm) and this is a temporary condition and will eventually return to normal operating condition.

Note. Clean the area around the connector to prevent contamination of the solenoid body connector.

Note. The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.

Scheme 258

Scheme 259

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
2. With the vehicle in PARK, position on a hoist.
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure.
5. Partially fill the transmission. For additional information, refer to «TRANSMISSION FLUID DRAIN AND REFILL - WITHOUT TORQUE CONVERTER DRAIN PLUG»(ref-194049-S42751872242005092600000) .

Scheme 260

1. Install the special tools into the transmission case.

Scheme 261

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Scheme 263

1. Using the special tools, install the main control valve body and loosely install the screws. Install the short screw. Install the screw with the larger head. Install the remaining screws.
2. Remove the special tools, and loosely install the screw.
3. Tighten the screws in the sequence shown.

Scheme 264

1. Install the reverse servo. Tighten the screws in the sequence shown.

Scheme 265

1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid.

Items 11, 12 and 13: Solenoid Body and Screws Installation Note

1. Install the solenoid body. Tighten the screws in sequence shown.

Item 10: Transmission Fluid Pan Filter Installation Note

1. Lubricate the seals and install the transmission fluid filter.

Scheme 266

1. Install the transmission fluid pan and gasket and loosely install the screws.

Scheme 267

1. Tighten the screws in a crisscross sequence.

Item 5: Solenoid Body Harness Electrical Connector Installation Note

1. Install and lubricate new O-ring seals on the transmission connector and connect the connector.

Scheme 268

Scheme 269

1. Remove the driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-194029) .
2. Remove the components in the order indicated in the following illustration and table.
3. To install, reverse the removal procedure.

Scheme 270

1. Using the special tools, remove the extension housing seal.

Item 1: Output Shaft Seal Installation Note

Note. Make sure the extension housing seal is correctly installed onto the special tool and the garter spring is in the correct position.

Scheme 271

1. Using the special tool, install the extension housing seal.

Scheme 272

Scheme 273

1. Remove the transfer case assembly. For additional information, refer to FOUR-WHEEL DRIVE SYSTEMS .
2. Remove the components in the order indicated in the following illustration and table.
3. To install, reverse the removal procedure.
4. Carry out fluid level check. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK»(ref-194049-S00442207332005092600000) .

Scheme 274

1. Using the special tools, remove the extension housing seal.

1. Using the special tool, install the extension housing seal.

Scheme 275

1. Remove the driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-194029) .
2. Support the transmission with a suitable jack.
3. Remove the rear transmission support insulator. For additional information, refer to «TRANSMISSION SUPPORT INSULATOR - 4X2»(ref-194049-S01352333112005092600000) .
4. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure.
6. Carry out fluid level check. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK»(ref-194049-S00442207332005092600000) .

Item 2: Extension Housing Removal Note

1. Remove the extension housing.

Item 2: Extension Housing Installation Note

1. Install the extension housing.

Scheme 276

1. Remove the transfer case assembly. For additional information, refer to FOUR-WHEEL DRIVE SYSTEMS .
2. Remove the components in the order indicated in the following illustration and table.
3. To install, reverse the removal procedure.
4. Carry out fluid level check. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK»(ref-194049-S00442207332005092600000) .

1. Remove the extension housing.

1. Install the extension housing.

Scheme 277

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 may experience slightly different upshifts (either soft or firm) and this is a temporary condition and will eventually return to normal operating condition.

Scheme 278

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
2. With the vehicle in PARK, position on a hoist.
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure.
5. Verify that the shift-cable is adjusted correctly. For additional information, refer to «SELECTOR LEVER CABLE ADJUSTMENT»(ref-194049-S06739298812005092600000) .

Scheme 279

1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid.

Item 10 and 11: Solenoid Body Screws Installation Note

1. Install the solenoid body. Tighten the screws in the sequence shown.

Scheme 280

1. Install the transmission fluid pan and gasket and loosely install the screws.

Scheme 281

1. Tighten the screws in a crisscross sequence.

Item 4: Solenoid Body Harness Electrical Connector Installation Note

1. Install and lubricate new O-ring seals on the transmission connector and connect the connector.

Scheme 282

Scheme 283

1. On 4x4 vehicles, remove the front driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-194029) .
2. On 4x2 vehicles, with the vehicle in NEUTRAL, position on a hoist.
3. It is not necessary to remove the shift cable and bracket from the transmission.
4. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure
6. Refill the transmission with the specified fluid.
7. Verify that the shift cable is adjusted correctly. For additional information, refer to «SELECTOR LEVER CABLE ADJUSTMENT»(ref-194049-S06739298812005092600000) .

Scheme 284

Scheme 285

1. Move the rubber boot back to gain access to the connector.
2. Disconnect the digital TR sensor connector.

Item 6: TR Sensor Installation Note

1. Install the digital TR sensor and loosely install the screws.

Item 5: TR Sensor Screws Installation Note

1. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.

Scheme 286

Scheme 287

1. Connect the digital TR sensor connector.
2. Move the rubber boot back over the connector.

Scheme 288

Note. The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.

Scheme 289

1. With the vehicle in PARK, position on a hoist.
2. Remove the components in the order indicated in the following illustration and table.
3. To install, reverse the removal procedure.
4. Partially fill the transmission. For additional information, refer to «TRANSMISSION FLUID DRAIN AND REFILL - WITHOUT TORQUE CONVERTER DRAIN PLUG»(ref-194049-S42751872242005092600000) .

Scheme 290

1. Install the reverse servo. Tighten the screws in the sequence shown in two stages. Stage 1: Tighten screws to 5 Nm (44 lb-in) Stage 2: Tighten screws to 11 Nm (8 lb-ft)

Scheme 291

1. Install the transmission fluid pan and gasket, and loosely install the screws.

Scheme 292

1. Tighten the screws in a crisscross sequence.

Scheme 293

Scheme 294

Removal

Note. If damage to the park gear is found, the transmission must be removed and disassembled to install a new park gear.

Note. The park pawl, park pawl return spring and the park pawl shaft may fall out when removing the extension housing.

Note. The transmission fluid pan gasket is reusable. Clean and inspect. If damage to the gasket is found, a new gasket must be installed.

Scheme 295

Scheme 296

1. On 4x4 vehicles, remove the transfer case assembly. For additional information, refer to FOUR-WHEEL DRIVE SYSTEMS .
2. On 4x2 vehicles, remove the driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-194029) .
3. On 4x2 vehicles, remove the rear transmission support insulator. For additional information, refer to «TRANSMISSION SUPPORT INSULATOR - 4X2»(ref-194049-S01352333112005092600000) .
4. On 4x2 vehicles, remove the exhaust. For additional information, refer to «EXHAUST SYSTEM»(ref-194051) .
5. It is not necessary to remove the shift cable and bracket from the transmission.
6. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and table.

Scheme 297

Scheme 298

1. Move the rubber boot back to gain access to the connector.
2. Disconnect the digital TR sensor connector.

Item 15: Manual Control Lever Inner Nut Removal Note

1. Remove the manual control lever inner nut.

Scheme 299

Scheme 300

1. Disconnect the manual valve inner lever from the parking lever actuating rod.
2. Remove the manual valve inner lever.

Scheme 301

Scheme 302

1. Illustration 2 of 2. Install the components in the order indicated in the following illustration and table.
2. On 4x4 vehicles, install the transfer case assembly. For additional information, refer to FOUR-WHEEL DRIVE SYSTEMS .
3. On 4x2 vehicles, install the driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-194029) .
4. On 4x2 vehicles, install the rear transmission support insulator. For additional information, refer to «TRANSMISSION SUPPORT INSULATOR - 4X2»(ref-194049-S01352333112005092600000) .
5. On 4x2 vehicles, install the exhaust. For additional information, refer to «EXHAUST SYSTEM»(ref-194051) .
6. Partially fill the transmission. For additional information, refer to «TRANSMISSION FLUID DRAIN AND REFILL - WITHOUT TORQUE CONVERTER DRAIN PLUG»(ref-194049-S42751872242005092600000) .

Scheme 303

1. Install and assemble the manual valve inner lever and parking pawl actuating rod as shown.

Item 3: Manual Control Lever Shaft Installation Note

1. Align the flats on the manual valve inner lever with the flats on the manual control lever shaft. Install the manual valve inner lever and parking lever actuating rod onto the manual control lever shaft.

Scheme 304

1. Install the manual valve inner lever onto the manual shaft and loosely install the nut.

Item 5: Manual Control Lever Shaft Retaining Pin Installation Note

1. Install the manual control lever shaft spring pin. Tap the manual control lever shaft spring pin into the transmission case.

Item 6: Manual Control Lever Inner Nut Installation Note

1. Tighten the nut.

Item 7: Manual Valve Detent Spring Installation Note

1. With the manual lever in the NEUTRAL position, install the manual valve detent spring.

Item 13: Extension Housing Installation Note

1. Install the 4x4 extension housing.
2. Install the 4x2 extension housing.

Item 15: Transmission Fluid Filter Installation Note

1. Lubricate the seals and install the transmission fluid filter.

Scheme 305

1. Install the transmission fluid pan and gasket and loosely install the screws.

Scheme 306

1. Tighten the screws in a crisscross sequence.

Item 21: TR Sensor Installation Note

1. Install the digital TR sensor and loosely install the screws.

Item 22: TR Sensor Screws Installation Note

1. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.

Scheme 307

Scheme 308

1. Connect the digital TR sensor connector.
2. Move the rubber boot back over the connector.

Scheme 309

1. With the vehicle in PARK, position on a hoist.
2. Support the transmission with a transmission jack.
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure.

Scheme 310

1. Raise the transmission up to gain access to the rear transmission mount.

Scheme 311

1. With the vehicle in PARK, position on a hoist.
2. Support the transmission with a transmission jack.
3. Remove the components in the order indicated the following illustration and table.
4. To install, reverse the removal procedure.

Item 10: Exhaust Hanger Removal Note

1. Position the hanger out of the way.

Item 10: Exhaust Hanger Installation Note

1. Install the exhaust hanger prior to installing the screw for the rear support insulator.

Note. Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.

Scheme 312

Scheme 313

1. On 4x4 vehicles, remove the front driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-194029) DRIVELINE SYSTEM .
2. For 4x2 vehicles, with the vehicle in PARK, position on a hoist.
3. Remove the shift cable and bracket.
4. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure.

Scheme 314

1. Remove the TSS sensor. Remove the TSS sensor screw. Remove the TSS sensor from the transmission. Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring.

Scheme 315

1. Inspect and lubricate the O-ring with petroleum jelly. Install the TSS sensor into the transmission. Tighten the screw.

Note. Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.

Scheme 316

Scheme 317

1. On 4x4 vehicles, remove the front driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-194029) .
2. For 4x2 vehicles, with the vehicle in PARK, position on a hoist.
3. Remove the shift cable and bracket.
4. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure.

Scheme 318

1. Remove the OSS sensor. Remove the OSS sensor screw. Remove the OSS sensor from the transmission. Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.

Scheme 319

1. Inspect and lubricate the O-ring with petroleum jelly. Install the OSS sensor into the transmission. Tighten the screw.

Note. Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.

Scheme 320

Scheme 321

1. On 4x4 vehicles, remove the front driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-194029) .
2. For 4x2 vehicles, with the vehicle in PARK, position on a hoist.
3. Remove the shift cable and bracket.
4. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure.

Scheme 322

1. Remove the intermediate shaft speed sensor.
2. Remove the intermediate shaft speed sensor screw.
3. Remove the intermediate shaft speed sensor from the transmission. Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring.

Scheme 323

1. Inspect and lubricate the O-ring with petroleum jelly. Install the intermediate shaft speed sensor into the transmission. Tighten the screw.

Scheme 324

Note. The 4x4 vehicle is shown in this procedure, the 4x2 vehicle is similar.

Scheme 325

Scheme 326

1. With the vehicle in PARK, position on a hoist.
2. Remove the components in the order indicated in the following illustration and table. To remove individual components, carry out the following steps.
3. To install, reverse the removal procedure.

Scheme 327

Scheme 328

1. Remove the pushpins from the LH side air deflector.
2. Remove the pushpins from the RH side air deflector.

Scheme 329

1. Position the lower air deflector out of the way.

Scheme 330

Scheme 331

Scheme 332

1. Remove the transmission fluid cooler hose fitting retaining clips.
2. Using the special tool, disconnect the fluid cooler line.
3. Using the special tool, disconnect the fluid cooler line.

Scheme 333

Scheme 334

1. Transfer the fluid cooler line brackets to the new lines.
2. Bend the tabs open to remove the bracket.
3. Remove the bracket.
4. Remove the bracket.

Scheme 335

1. Install the transmission fluid cooler hose fitting retaining clips.

Scheme 336

Scheme 337

1. Position the lower air deflector back in place and install the pushpins from the LH side air deflector.
2. Install the pushpins from the RH side air deflector.

Item 3: Transmission Selector Lever Cable Grommet Removal Note

1. Push the cable grommet through the floor pan.

Scheme 338

1. Remove the lower dash panel.
2. Remove the upper and lower steering column shrouds.
3. Place the range selector lever in the first gear position.
4. Place the range selector lever in the (D) position. This should be two detents from the first gear position.
5. Hand a three-pound weight on the end of the range selector lever.
6. Center the pointer in the middle of the (D) by rotating the thumbwheel on the PRNDL cable housing.
7. Remove the three-pound weight from the end of the range selector lever.
8. Install the upper and lower steering column shrouds.
9. Install the lower dash panel.

Item 6: Transmission Selector Lever Cable Installation Note

1. After installing the shift cable, it will be necessary to adjust the shift cable. For additional information, refer to «SELECTOR LEVER CABLE ADJUSTMENT»(ref-194049-S06739298812005092600000) .

Item 3: Transmission Selector Lever Cable Grommet Installation Note

1. The cable grommet must be seated up against the floor pan tightly or water may enter the passenger compartment.

Scheme 339

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.

Note. If disassembly or installation of a new transmission is necessary, drain the transmission fluid.

Scheme 340

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Scheme 343

Scheme 344

Scheme 345

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Scheme 347

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Scheme 350

Scheme 351

Scheme 352

Scheme 353

Scheme 354

1. With the vehicle in NEUTRAL, position on a hoist.
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
3. Remove the radiator appearance cover.
4. Remove the LH upper fan shroud bolt. If equipped, remove and discard the assembly screw(s).
5. Remove the upper fan shroud bolts. Remove the RH bolt. If equipped, remove and discard the RH assembly screw(s). If equipped, disconnect the A/C line retainer. Remove the fan shroud.
6. If equipped with a 4.OL engine, remove the exhaust manifold to exhaust gas recirculation (EGR) valve tube. For additional information, refer to «ENGINE-4.0L SOHC»(ref-194043) or «ENGINE-4.6L 2V»(ref-194045) .
7. If equipped with a 4.OL engine, tap the hole in the RH cylinder head in order to install the lifting hook. Use a 10 x 1.50 mm (0.06 in) tap to tap the hole.
8. If equipped with a 4.OL engine, install the special tool in the previously tapped hole.
9. If equipped with a 4.6L engine, remove the engine appearance cover.
10. If equipped with a 4.6L engine, remove the battery ground cable and the bracket. Position the bracket and wire harness out of the way.
11. If equipped with a 4.6L engine, install the special tool.
12. Install the special tools.
13. Remove the driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-194029) .
14. If equipped, remove the two bolts on the bracket and position aside.
15. Illustration 1 of 3. Remove in the order indicated in the following illustration and table.
16. Illustration 2 of 3. Remove in the order indicated in the following illustration and table.
17. Illustration 3 of 3. Remove in the order indicated in the following illustration and table.
18. If contamination is present, backflush and clean the transmission fluid cooler. For additional information, refer to «TRANSMISSION FLUID COOLER - BACKFLUSHING AND CLEANING»(ref-194049-S18434024522005092600000) .

Item 13: Transmission Assembly Removal Note

1. Install a suitable jack under the transmission.

Item 38: Solenoid Body Harness Connector Removal Note

1. Remove the screw from the solenoid body connector and disconnect the connector.

Scheme 355

Item 42: Fluid Cooler Nuts Removal Note

1. Disconnect the transmission cooler tubes.

Scheme 356

Item 44: Fuel Line Bracket Removal Note

1. Position the bracket and fuel lines out of the way to gain access to the other transmission retaining screws.

Scheme 357

Scheme 358

Scheme 359

Scheme 360

1. Vehicles equipped with a 4.6L engine, remove the front crossmember.
2. Vehicles equipped with a 4.6L engine, remove the seven engine-to-transmission retaining bolts.
3. Vehicles equipped with a 4.OL engine, remove the six engine-to-transmission retaining bolts and position the fuel line bracket out of the way.
4. Install the special tool.

Scheme 361

Scheme 362

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.

Note. If disassembly or installation of a new transmission is necessary, drain the transmission fluid. Install the drain plug when finished.

Scheme 363

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Scheme 373

Scheme 374

Scheme 375

1. With the vehicle in NEUTRAL, position on a hoist.
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
3. Remove the radiator appearance cover.
4. Remove the LH upper fan shroud bolt. If equipped, remove and discard the assembly screw(s).
5. Remove the upper fan shroud bolts. Remove the RH bolt. If equipped, remove and discard the RH assembly screw(s). If equipped, disconnect the A/C line retainer. Remove the fan shroud.
6. If equipped with a 4.0L engine, remove the exhaust manifold to exhaust gas recirculation (EGR) valve tube. For additional information, refer to «ENGINE-4.0L SOHC»(ref-194043) or «ENGINE-4.6L 2V»(ref-194045) .
7. If equipped with a 4.OL engine, tap the hole in the RH cylinder head in order to install the lifting hook. Use a 10 x 1.50 mm (0.06 in) tap to tap the hole.
8. If equipped with a 4.0L engine, install the special tool in the previously tapped hole.
9. If equipped with a 4.6L engine, remove the engine appearance cover.
10. If equipped with a 4.6L engine, remove the battery ground cable and the bracket. Position the bracket and wire harness out of the way.
11. If equipped with a 4.6L engine, install the special tool.
12. Install the special tools.
13. Remove the front and rear driveshafts. For additional information, refer to «DRIVELINE SYSTEM»(ref-194029) .
14. Illustration 1 of 3. Remove in the order indicated in the following illustration and table.
15. Illustration 2 of 3. Remove in the order indicated in the following illustration and table.
16. Illustration 3 of 3. Remove in the order indicated in the following illustration and table.
17. If contamination is present, backflush and clean the transmission fluid cooler. For additional information, refer to «TRANSMISSION FLUID COOLER - BACKFLUSHING AND CLEANING»(ref-194049-S18434024522005092600000) .

Scheme 376

1. Install a suitable jack stand under the transfer case.

Item 42: Solenoid Body Harness Connector Removal Note

1. Remove the screw from the solenoid body connector and disconnect the connector.

Item 47: Fluid Cooler Nuts Removal Note

Disconnect the transmission cooler tubes.

Scheme 377

Item 48: Transmission Assembly Removal Note

Support the transmission with a transmission jack.

Remove the jack stand from under the transfer case.

Scheme 378

Item 50: Fuel Line Bracket Removal Note

Position the bracket and fuel lines out of the way to gain access to the other transmission retaining screws.

Scheme 379

Scheme 380

Scheme 381

Scheme 382

1. Vehicles equipped with a 4.6L engine, remove the front crossmember.
2. Vehicles equipped with a 4.6L engine, remove the seven engine-to-transmission retaining bolts.
3. Vehicles equipped with a 4.0L engine, remove the six engine-to-transmission retaining bolts and position the fuel line bracket out of the way.
4. Lower the transmission and transfer case as an assembly from the vehicle.
5. Install the special tool.
6. Remove the transfer case from the back of the transmission. Remove the screws and the bracket. Disconnect the vent hose.

Scheme 383

Scheme 384

Scheme 385

Scheme 386

Item 3: Fuel Line Bracket Installation Note

1. Position the fuel line bracket in place prior to installing the remaining transmission retaining screws.

Scheme 387

1. Install the transmission fluid cooler tubes.
2. 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 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.

Item 12: Solenoid Body Harness Connector Installation Note

1. Install and lubricate new O-ring seals on the transmission connector and connect the connector.

Item 31: Rear Transmission Support Nuts Installation Note

1. Loosely install the rear transmission support nuts.

Scheme 388

1. Remove the transmission jack.
2. If equipped, install the cable bracket and the two bolts.

Scheme 389

Scheme 390

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Scheme 394

1. Secure the transmission to the transmission jack with a safety chain.
2. Illustration 1 of 3. Install the components in the order indicated in the following illustration and table.
3. Illustration 2 of 3. Install the components in the order indicated in the following illustration and table.
4. Illustration 3 of 3. Install the components in the order indicated in the following illustration and table.
5. Install the driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-194029) .
6. Connect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
7. Carry out the fluid level check. For additional information, refer to «TRANSMISSION FLUID LEVEL CHECK»(ref-194049-S00442207332005092600000) .
8. Verify that the shift cable is correctly adjusted. For additional information, refer to «SELECTOR LEVER CABLE ADJUSTMENT»(ref-194049-S06739298812005092600000) .
9. Check the operation of the transmission and inspect for leaks.

Scheme 395

Scheme 396

Scheme 397

1. If removed, install the transfer case to the back of the transmission, install the bracket and connect the vent hose.
2. Remove the special tool.
3. On vehicles equipped with a 4.6L engine, install the seven engine-to- transmission retaining bolts.
4. On vehicles equipped with a 4.0L engine, position the fuel line bracket in place and install the six retaining bolts.
5. Install the front crossmember
6. Raise and position the transmission and transfer case to the back of the engine. Remove the special tool prior to attaching the transmission to the engine.

1. Position the fuel line bracket in place prior to installing the remaining transmission retaining screws.

Scheme 398

1. Install the transmission fluid cooler tubes.
2. 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 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.

1. Install and lubricate new O-ring seals on the transmission connector and connect the connector.

Item 32: Rear Transmission Support Nuts Installation Note

1. Loosely install the rear transmission support nuts.

Item 36: Transmission Assembly Installation Note

1. Remove the transmission jack.