Automatic Transaxle/transmission: Removal & Installation Lincoln Aviator I

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 273

1. On 4x4 vehicles, remove the transfer case assembly. For additional information, refer to «FOUR WHEEL DRIVE SYSTEMS»(ref-193007) .
2. On 4x2 vehicles, remove the driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-192998) .
3. On 4x2 vehicles, remove the rear transmission support insulator. For additional information, refer to «TRANSMISSION SUPPORT INSULATOR - 4x2»(ref-193005-S34180973482005092300000) .
4. On 4x2 vehicles, remove the exhaust. For additional information, refer to «EXHAUST SYSTEM»(ref-193008) .
5. It is not necessary to remove the shift cable and bracket from the transmission.
6. Remove the components in the order indicated in the following illustration.

Scheme 274

Item 1: Transmission Range (TR) Sensor Electrical Connector Removal Note

Scheme 275

Scheme 276

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.

Item 18: Manual Control Valve Detent Inner Lever Removal Note

Scheme 277

Scheme 278

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

Scheme 279

Scheme 280

1. Install the components in the order indicated in the following illustration.
2. On 4x4 vehicles, install the transfer case assembly. For additional information, refer to «FOUR WHEEL DRIVE SYSTEMS»(ref-193007) .
3. On 4x2 vehicles, install the driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-192998) .
4. On 4x2 vehicles, install the rear transmission support insulator. For additional information, refer to «TRANSMISSION SUPPORT INSULATOR - 4x2»(ref-193005-S34180973482005092300000) .
5. On 4x2 vehicles, install the exhaust. For additional information, refer to «EXHAUST SYSTEM»(ref-193008) .
6. Partially fill the transmission. For additional information, refer to «TRANSMISSION FLUID DRAIN AND REFILL - WITHOUT TORQUE CONVERTER DRAIN PLUG»(ref-193005-S15199184222005092300000) .

Item 2: Manual Control Valve Detent Inner Lever Installation Note

Scheme 281

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.

Item 4: Manual Control Lever Inner Nut Installation Note

Scheme 282

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

Scheme 283

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.

Item 18: Transmission Fluid Pan Installation Note

Scheme 284

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

Item 19: Transmission Fluid Pan Screws Installation Note

Scheme 285

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.

Item 26: TR Sensor Electrical Connector Installation Note

Scheme 286

Scheme 287

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

Scheme 288

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.
4. To install, reverse the removal procedure.

Item 3: Transmission Case Removal Note

Scheme 289

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

Scheme 290

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.
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.