Thursday, March 8, 2012

Ford Explorer Transmission A340E Removal & Installation Procedure?

The procedure will work for Lincoln Aviator, Ford Explorer, Exp Sport, Exp Sport-Trac, Mercury Mountaineer 2000-2005.


Transmission Removal & Installation:---
A340E

The details are as follows :----

Before servicing the vehicle, refer to the Precautions section.
Drain the transmission fluid.
Place the transmission in Neutral .

Remove or disconnect the following:
Negative battery cable
Fluid level indicator

Fan shroud
Transfer case on 4WD vehicles
Rear driveshaft after matchmarking the yoke and axle flange
Starter
Access cover and adapter plate bolts from the lower left side of the converter housing, on all other applications
Flywheel-to-converter attaching nuts. Use a socket and breaker bar on the crankshaft pulley attaching bolt. Rotate the pulley clockwise as viewed from the front to gain access to each of the nut
Shifter cable
Transmission wire harness
Heated Oxygen (HO 2 S) sensor connector
Transmission connector
Digital Transmission Range (TR) sensor connector
Catalytic converter

Speedometer cable and/or vehicle speed sensor from the transfer case (4WD) or extension housing (2WD)
Transmission cooler lines
Engine rear support-to-crossmember bolts and the crossmember-to-frame side support attaching nuts and bolts
Crossmember

Transmission mount
Transmission upper fill tube
Vent tube on 4WD vehicles
Converter housing-to-engine bolts

Move the transmission to the rear so it disengages from the dowel pins and the converter is disengaged from the flywheel. Lower the transmission from the vehicle.
Remove the torque converter from the transmission, if necessary.

To install:
Install the converter on the transmission.
WARNING
Before installing an automatic transmission, always check that the torque converter is fully seated into the transmission. Typically, the converter has notches or tangs on the hub that must engage the transmission fluid pump. If they are not engaged in the pump, the transmission will not mate to the engine properly, as the converter will be holding it away. Severe damage to the pump, converter or transmission casting can occur if the transmission-to-engine bolts are tightened to force the transmission to mate to the engine.

Proper installation of the converter requires full engagement of the converter hub in the pump gear. To accomplish this, the converter must be pushed and at the same time rotated through what feels like 2 notches or bumps. When fully installed, rotation of the converter will usually result in a clicking noise heard, caused by the converter surface touching the housing to case bolts.

For reference, a properly installed converter will have a distance from the converter pilot nose from face-to-converter housing outer face of 13 / 32 - 9 / 16 in. (10.5-14.5mm).

Rotate the converter so that the drive studs are in alignment with the holes in the flywheel.

Move the converter and transmission assembly forward into position, being careful not to damage the flywheel and converter pilot. The converter housing is piloted into position by the dowels in the rear of the engine block.

NOTE
During this move, to avoid damage, do not allow the transmission to get into a nose down position as this will cause the converter to move forward and disengage from the pump gear.

Install or connect the following:
Converter housing to engine. Torque the bolts to 30-41 ft. lbs. (40-55 Nm). The 2 longer bolts are located at the dowel holes.

Upper fluid filler tube and bracket. Torque the bolt to 41 ft. lbs. (55 Nm).
Transfer case, 4WD vehicles
Exhaust bracket. Torque the bolts to 64 ft. lbs. (87 Nm).
Crossmember. Torque the bolts to 87 ft. lbs. (118 Nm).
Transmission mount. Torque the bolts to 81 ft. lbs. (110 Nm).
Transmission cooler lines. Torque the bolts to 23 ft. lbs. (31 Nm).
Starter. Torque the bolts to 30 ft. lbs. (40 Nm).
Transmission wire harness

HO 2 S sensor
Transmission connector
TR sensor connector
Shift cable and bracket
Driveshaft. Torque the bolts to 95 ft. lbs. (129 Nm).
Shroud. Torque the bolts to 71 inch lbs. (8 Nm).
Fluid level indicator
Negative battery cable

Fill the transmission to the proper level.
Start the vehicle and check for leaks, repair if necessary.
Before servicing the vehicle, please familiarize yourself with safety procedures.
Place the transmission in Neutral
Remove or disconnect the following:
Negative battery cable
Transfer case
Three-way catalytic converter
If transmission disassembly is necessary, drain the transmission fluid.
Support the transmission with a transmission jack.
Remove or disconnect the following:

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

Right heat shield
Left heat shield bolt
Plastic cover from the right side of the frame rail
Plastic shield on the right side of the crossmember near the fuel tank
The two upper crossmember bolts (two on each side)
Right side lower crossmember bolts
Left side lower crossmember bolts
Transmission support insulator nuts and remove the crossmember
The two bolts and remove the transmission support insulator
Shift cable and bracket

Turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor and intermediate shaft speed (ISS) sensor electrical connectors

Remove or disconnect the following:
WARNING
Do not damage the cooler tubes
NOTE
Make an identifying mark on the nut, stud, and adapter plate to allow for correct installation.
Screw from the solenoid body connector and disconnect the connector
Harness retainers
Left side heated oxygen sensor (HO2S) connector from the bracket
Digital transmission range (TR) sensor connector
Starter

Transmission cooler tubes
Access cover
The 4 torque converter nuts
The 7 engine-to-transmission retaining bolts
Lower the transmission from the vehicle.

To install:
Raise and position the transmission.
Align the flexplate to converter marks made at removal.
Install seven engine to transmission retaining bolts. Torque to 35 ft. lbs. (48 Nm).
Install the four torque converter nuts. Torque to 28 ft. lbs. (48 Nm).

Install or connect the following:
WARNING
Damage will occur to the solenoid body assembly if the screw is tightened above 44 inch lbs. (5 Nm). Always install new O-ring seals on vehicle harness connector. Clean the area around connector to prevent contamination of the solenoid body connector. Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.

Access cover
Transmission cooler tubes
Starter
Digital transmission range (TR) sensor connector
Left side heated oxygen sensor (HO2S) to the bracket
Wire harness, and install the retainers


Install and lubricate new O-ring seals on the transmission connector and connect the connector.
Install or connect the following:

NOTE
Ford recommends, if the vehicle was not equipped with a fluid filter, install a Fluid Filter Service Kit (XC3Z-7B155-AA). Follow the instructions supplied in the kit. If the vehicle was equipped with a fluid filter, install a new filter (XC3Z-7B155-AB).

Turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor, and intermediate shaft speed (ISS) sensor electrical connectors.

Shift cable and bracket
Three-way catalytic converter
Transmission support insulator. Torque to 68 ft. lbs. (90 Nm).

Crossmember in place and loosely install the two nuts to hold up the crossmember.
Crossmember bolts. Torque to 52 ft. lbs. (70 Nm).
Rear transmission support nuts. Torque to 52 ft. lbs. (70 Nm).

Heat shields
Plastic cover to the right side of the frame rail
Plastic shield on the right side of the crossmember near the fuel tank
Transfer case
Connect the battery ground cable.
Verify that the shift cable is correctly adjusted.
Before servicing the vehicle, refer to the precautions in the beginning of this section.
Place the transmission in Neutral .
Remove or disconnect the following:

Negative battery cable
Transfer case
Three-way catalytic converter
If transmission disassembly is necessary, drain the transmission fluid.
Support the transmission with a transmission jack.
Remove or disconnect the following:

NOTE
Clean the area around connector to prevent contamination of the solenoid body connector.
RH heat shield
LH heat shield bolt
Plastic cover from the right side of the frame rail
Plastic shield on the right side of the crossmember near the fuel tank
The two upper crossmember bolts (two on each side)
RH side lower crossmember bolts
LH side lower crossmember bolts
Transmission support insulator nuts and remove the crossmember
The two bolts and remove the transmission support insulator
Shift cable and bracket

Turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor and intermediate shaft speed (ISS) sensor electrical connectors



Remove or disconnect the following:

WARNING
Do not damage the cooler tubes


NOTE
Make an identifying mark on the nut, stud, and adapter plate to allow for correct installation.



Screw from the solenoid body connector and disconnect the connector

Harness retainers

Left side heated oxygen sensor (HO2S) connector from the bracket

Digital transmission range (TR) sensor connector

Starter




Transmission cooler tubes

Access cover




The 4 torque converter nuts

The 7 engine-to-transmission retaining bolts



Lower the transmission from the vehicle.



To install:

Raise and position the transmission.

Align the flexplate to converter marks made at removal.

Install seven engine to transmission retaining bolts. Torque to 35 ft. lbs. (48Nm).

Install the four torque converter nuts. Torque to 28 ft. lbs. (48Nm).

Install or connect the following:

WARNING
Damage will occur to the solenoid body assembly if the screw is tightened above 44 inch lbs. (5Nm). Always install new O-ring seals on vehicle harness connector. Clean the area around connector to prevent contamination of the solenoid body connector. Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.



Access cover

Transmission cooler tubes

Starter

Digital transmission range (TR) sensor connector

Left side heated oxygen sensor (HO2S) to the bracket

Wire harness, and install the retainers



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

Install or connect the following:

NOTE
If the vehicle was not equipped with a fluid filter, install a Fluid Filter Service Kit (XC3Z-7B155-AA). Follow the instructions supplied in the kit. If the vehicle was equipped with a fluid filter, install a new filter (XC3Z-7B155-AB).



Turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor, and intermediate shaft speed (ISS) sensor electrical connectors.

Shift cable and bracket

Three-way catalytic converter

Transmission support insulator. Torque to 68 ft. lbs. (90Nm).

Crossmember in place and loosely install the two nuts to hold up the crossmember.

Crossmember bolts. Torque to 52 ft. lbs. (70Nm).

Rear transmission support nuts. Torque to 52 ft. lbs. (70Nm).

Heat shields

Plastic cover to the right side of the frame rail

Plastic shield on the right side of the crossmember near the fuel tank

Transfer case



Connect the battery ground cable.

Verify that the shift cable is correctly adjusted.




A340e

2-Wheel Drive


Before servicing the vehicle, please familiarize yourself with safety procedures.

NOTE
When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy.


Disconnect the battery ground cable.

Remove the fan shroud bolts. Do not remove the fan shroud.

Raise and support the vehicle.

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

Remove the 2 right side heat shield bolts and position the shield aside.

Disconnect the 2 heated oxygen sensor electrical connectors.

Disconnect the 2 catalyst monitor sensor electrical connectors.

Remove the right side heat shield bolts.

Remove the right side heat shield bolt and remove the heat shield.

Remove the left side heat shield bolt.

Remove the 2 nuts and the plastic shield on the right side of the crossmember near the fuel tank.

Remove the 4 upper crossmember bolts (2 on each side).

Remove the bolts, springs, flag nuts and separate the muffler from the converter. Discard the gasket. Discard the flag nuts.

Remove the 4 converter-to-manifold nuts.

Remove the jack stand and lower the converter assembly with the heat shield.

CAUTION
Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.


Install a suitable jack under the transmission.

Remove the right side crossmember bolts.

Remove the left side crossmember bolts.

Remove the 2 bolts on the bracket and position aside.

Remove the transmission support insulator nuts and remove the crossmember.

NOTE
This step may require an assistant.


Remove the transmission mounted exhaust hanger and the 3-way converter assembly.

Remove the shift cable and bracket and position out of PARK.

Index-mark the location of the rear flange and pinion flange. Remove the 4 bolts. Remove the rear driveshaft pinion flange bolts.

NOTE
Do not use a hammer.


Remove the driveshaft flange from the pinion flange, using a pry bar.

Index-mark the driveshaft and the extension housing. Remove the driveshaft from the vehicle.

Remove the electrical connector cover.

Remove the starter wire and positive battery cable.

Remove the starter motor bolts and starter.

Remove the flexplate cover.

Remove the access cover.

NOTE
Make an identifying mark on the nut, stud and flexplate to allow for correct installation.


Remove the 4 torque converter nuts.

Lower the transmission to gain access to the sensor connectors and the transmission bolts.

Disconnect the right side catalyst monitor connector and the fuel lines from the bracket.

Disconnect the right side heated oxygen sensor from the transmission.

Disconnect the left side heated oxygen sensor and the harness clip from the transmission.

Disconnect the left side catalyst monitor connector from the transmission.

Move the rubber boot back to gain access to the connector. Disconnect the digital transmission range (TR) sensor connector.

Disconnect the turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor and intermediate shaft speed (ISS) sensor electrical connectors.

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


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

Disconnect the harness retainers.

WARNING
Do not damage the cooler tubes.


Disconnect the transmission cooler tubes.

Remove the front crossmember.

Remove the 7 engine-to-transmission retaining bolts.

Lower the transmission assembly from the vehicle.

Install special tool 307-346 to hold the torque converter.

Carry out the transmission fluid cooler back flushing and cleaning if the transmission is being overhauled or installing a new or remanufactured transmission.



To install

CAUTION
Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.


Secure the transmission to the transmission jack with a safety chain.

NOTE
Rotate the torque converter so the orange or green paint daub is in the 12 o'clock position.


Raise and position the transmission to the back of the engine.

Install the 7 engine-to-transmission retaining bolts. Tighten to 35 ft. lbs. (48 Nm).

Install the 4 torque converter nuts. Tighten to 28 ft. lbs. (38 Nm).

Install the access cover.

Install the flexplate cover. Tighten to 25 ft. lbs. (34 Nm).

Install the starter. Tighten to 18 ft. lbs. (24 Nm).

Install the starter motor electrical connectors. Tighten to 115 inch lbs. (13 Nm).

Install the starter motor electrical connector cover.

Install the front crossmember. Tighten to 62 ft. lbs. (70 Nm).

WARNING
Use care not to bend or force the cooler tubes otherwise damage to the cooler tubes and the transmission can result.


Install the transmission fluid cooler tubes. Tighten to 22 ft. lbs. (30 Nm).

Connect the digital transmission range (TR) sensor connector. Move the rubber boot back over the connector.

Connect the left side heated oxygen sensor (HO 2 S) to the transmission and install the wire harness retainer. Position the wire harness and install the retainers.

WARNING
Damage will occur to the solenoid body assembly if the screw is tightened above the specification.


NOTE
Always install new O-ring seals on the vehicle harness connector.


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


NOTE
Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.


Install and lubricate new O-ring seals on the transmission connector and connect the connector. Tighten to 44 inch lbs. (5 Nm).

Connect the left side catalyst monitor connector to the transmission.

Connect the right side heated oxygen sensor (HO 2 S) to the transmission.

Connect the fuel lines and the right side catalyst monitor connector to the bracket.

Connect the turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor and intermediate shaft speed (ISS) sensor electrical connectors.

NOTE
This step may require an assistant.


Position the catalytic converter assembly with heat shield and loosely install the 4 converter-to-manifold nuts.

Install the rear transmission mount bolts. Tighten to 66 ft. lbs. (90 Nm).

Connect the 2 heated oxygen sensor electrical connectors.

Connect the 2 catalyst monitor sensor electrical connectors.

Position the crossmember in place and loosely install the 2 nuts to hold up the crossmember.

NOTE
Using a transmission jack, raise the crossmember into place.


Install the right side crossmember bolts. Tighten to 52 ft. lbs. (70 Nm).

Install the left side crossmember bolts. Tighten to 52 ft. lbs. (70 Nm).

Remove the transmission jack.

Install the 4 upper crossmember bolts (2 on each side). Tighten to 52 ft. lbs. (70 Nm).

Tighten the rear transmission mount nuts. Tighten to 66 ft. lbs. (90 Nm).

Install the cable bracket and 2 bolts. Tighten to 30 ft. lbs. (40 Nm).

Install the heat shield bolts. Tighten to 15 ft. lbs. (20 Nm).

Install the right side heat shield and 2 bolts. Tighten to 15 ft. lbs. (20 Nm).

Install the left side heat shield bolts. Tighten to 15 ft. lbs. (20 Nm).

Install the plastic shield on the right side of the crossmember near the fuel tank. Tighten to 80 inch lbs. (9 Nm).

Tighten the 4 converter-to-manifold nuts. Tighten to 30 ft. lbs. (40 Nm).

Using a new gasket install the converter-to-muffler pipe. Install the bolts, springs and flag nuts. Tighten to 30 ft. lbs. (40 Nm).

Align the marks made during removal. Install the front portion of the driveshaft into the transmission.

WARNING
If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with Threadlock and Sealer TA-25 or equivalent meeting Ford specification WSK-M2G351-A5.


WARNING
The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in a cross pattern as shown.


Align the marks made during removal. Install the rear driveshaft and bolts. Tighten to 83 ft. lbs. (112 Nm).

Install the shift cable and bracket. Tighten to 30 ft. lbs. (40 Nm).

Use the following guidelines for installing 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.

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 up shifts (either soft or firm) and that this is a temporary condition and will eventually return to normal operating condition.




Connect the battery ground cable.

Position the fan shroud and install the bolts.

Carry out the fluid level check.

Verify that the shift cable is correctly adjusted.

Check the operation of the transmission and inspect for leaks.



Before servicing the vehicle, please familiarize yourself with safety procedures.

NOTE
When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy.


Disconnect the battery ground cable.

Remove the fan shroud bolts. Do not remove the fan shroud.

Raise and support the vehicle.

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

Remove the 2 right heat shield bolts and position the right heat shield aside.

Disconnect the 2 heated oxygen sensor electrical connectors.

Disconnect the 2 catalyst monitor sensor electrical connectors.

Remove the right heat shield bolts.

Remove the right heat shield bolt and remove the heat shield.

Remove the left heat shield bolt.

Remove the plastic shield on the right side of the crossmember near the fuel tank.

Remove the 2 upper crossmember bolts (2 on each side).

Remove the bolts, springs, flag nuts and separate the muffler from the converter. Discard the gasket.

Discard the flag nuts.

Remove the 4 converter-to-manifold nuts.

Install a suitable jack stand under the transfer case.

Remove the right side crossmember bolts.

Remove the left side crossmember bolts.

Remove the transmission support insulator nuts and remove the crossmember.

NOTE
This step may require an assistant.


Remove the transmission mounted exhaust hanger and the 3-way converter system.

Remove the shift cable and bracket.

Position the manual lever out of park.

Index-mark the front axle pinion flange and the front driveshaft.

Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.

Remove and discard the bolts and washers.

Remove and discard the bolts and universal joint retainers.

WARNING
Always disconnect the front driveshaft from the transfer case 1st. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.


WARNING
Tape the bearing cups to the driveshaft to prevent them from falling off of the spider.


NOTE
The front driveshaft CV-joint is not repairable.


Remove the driveshaft.

Mark the location of the flanges. Remove the rear driveshaft bolts.

NOTE
Do not use a hammer.


Remove the driveshaft from the flange using a pry bar.

4.6L engine

Remove the electrical connector cover.

Remove the starter wire and the positive battery cable.

Remove the starter motor bolts and starter.

Remove the flexplate cover.

Remove the access cover.

NOTE
Make an identifying mark on the nut, stud and flexplate to allow for correct installation.


Remove the 4 torque converter nuts.



4.0L engine

Remove the starter and position off to the side.

NOTE
Make an identifying mark on the nut, stud and flexplate to allow for correct installation.


Remove the 4 torque converter nuts.

Remove the lower transmission retaining bolts.



All vehicles

Lower the transmission to gain access to the sensor connectors and the transmission bolts.

Disconnect the right catalyst monitor connector and the fuel lines from the bracket.

Disconnect the right heated oxygen sensor from the transmission.

If equipped, disconnect the shift motor electrical connector.

Disconnect the left heated oxygen sensor and the harness clip from the transmission.

Disconnect the left catalyst monitor connector from the transmission.

Move the rubber boot back to gain access to the connector.

Disconnect the digital transmission range (TR) sensor connector.

Disconnect the turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor and intermediate shaft speed (ISS) sensor electrical connectors.

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


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

Disconnect the harness retainers.

WARNING
Do not damage the cooler tubes. Hold the transmission case fittings with a wrench.


Disconnect the transmission cooler tubes.

CAUTION
Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.


Support the transmission with a transmission jack.

Remove the jack stand from under the transfer case.



For 4.6L engines, perform the following:

Remove the 4 front crossmember bolts and the crossmember.

Remove the 7 engine-to-transmission retaining bolts.



For 4.0L engines, perform the following:

Remove the 6 engine-to-transmission retaining bolts and position the fuel line bracket aside.



For all vehicles:

Lower the transmission and transfer case as an assembly from the vehicle.

Install a converter holding tool.

NOTE
If the transmission is being serviced, the transfer case will need to be removed.


Remove the transfer case from the back of the transmission.

Carry out the transmission fluid cooler back flushing and cleaning if the transmission is being overhauled or installing a new or remanufactured transmission.





To install:

CAUTION
Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.


Secure the transmission to the transmission jack with a safety chain.

NOTE
Rotate the torque converter so that the torque converter paint mark is in the 12 o'clock position.


Raise and position the transmission to the back of the engine.

4.6L engine:

Install the 7 engine-to-transmission retaining bolts. Tighten to 35 ft. lbs. (48 Nm).

Install the 4 torque converter nuts. Tighten to 28 ft. lbs. (38 Nm).

Install the access cover.

Install the flexplate cover. Tighten to 25 ft. lbs. (34 Nm).

Install the starter. Tighten to 18 ft. lbs. (24 Nm).

Install the starter motor electrical connectors. Tighten the cable to 115 inch lbs. (13 Nm). Tighten the wire to 53 inch lbs. (6 Nm).

Install the starter motor electrical connector cover.

Install the front crossmember. Tighten to 52 ft. lbs. (70 Nm).



4.0L engine:

Position the fuel line bracket in place and install the 6 retaining bolts. Tighten to 35 ft. lbs. (48 Nm).

Install the 4 torque converter nuts. Tighten to 28 ft. lbs. (38 Nm).

Install the starter motor. Tighten to 18 ft. lbs. (25 Nm).

Install the lower transmission retaining bolts. Tighten to 35 ft. lbs. (48 Nm).



All vehicles:

WARNING
Use care not to bend or force the cooler tubes otherwise damage to the cooler tubes and the transmission can result.


Install the transmission fluid cooler tubes. Tighten to 22 ft. lbs. (30 Nm).

Connect the digital transmission range (TR) sensor connector. Move the rubber boot back over the connector.

Connect the left heated oxygen sensor (HO 2 S) to the transmission and install the wire harness retainer. Position the wire harness and install the retainers.

WARNING
Damage will occur to the solenoid body assembly if the screw is tightened above the specification.


NOTE
Always install new O-ring seals on the vehicle harness connector.


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


NOTE
Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.


Install and lubricate new O-ring seals on the transmission connector and connect the connector. Tighten to 44 inch lbs. (5 Nm).

Connect the left catalyst monitor connector to the transmission.

Connect the right heated oxygen sensor (HO 2 S) to the transmission.

Connect the fuel lines and the right catalyst monitor connector to the bracket.

Connect the turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor, and intermediate shaft speed (ISS) sensor electrical connectors.

NOTE
This step may require an assistant.


Position the catalytic converter assembly with heat shield and loosely install the 4 converter-to-manifold nuts.

Install the rear transmission mount bolts. Tighten to 66 ft. lbs. (90 Nm).

Connect the 2 heated oxygen sensor electrical connectors.

Connect the 2 catalyst monitor sensor electrical connectors.

Position the crossmember in place and loosely install the 2 nuts to hold up the crossmember.

NOTE
Using a transmission jack, raise the crossmember into place.


Install the right side crossmember bolts. Tighten to 52 ft. lbs. (70 Nm).

Install the left side crossmember bolts. Tighten to 52 ft. lbs. (70 Nm).

Remove the transmission jack.

Install the 2 upper crossmember bolts (2 on each side). Tighten to 52 ft. lbs. (70 Nm).

Tighten the rear transmission mount nuts. Tighten to 66 ft. lbs. (90 Nm).

Install the cable bracket and 2 bolts. Tighten to 30 ft. lbs. (40 Nm).

Install the heat shield bolts. Tighten to 15 ft. lbs. (20 Nm).

Install the right heat shield and 3 bolts. Tighten to 15 ft. lbs. (20 Nm).

Install the left heat shield bolts. Tighten to 15 ft. lbs. (20 Nm).

Install the plastic shield on the right side of the crossmember near the fuel tank. Tighten to 80 inch lbs. (9 Nm).

Tighten the 4 converter-to-manifold nuts. Tighten to 30 ft. lbs. (40 Nm).

Using a new gasket install the converter-to-muffler pipe. Install the bolts, springs and flag nuts. Tighten to 30 ft. lbs. (40 Nm).

Align the marks made during removal. Install the front portion of the driveshaft into the transmission.

WARNING
If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with Threadlock and Sealer TA-25 or equivalent meeting Ford specification WSK-M2G351-A5.


WARNING
The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in a cross pattern as shown.




image

Fig. Rear driveshaft flange torque sequence-2004-05 Explorer and Mountaineer

Align the marks made during removal. Install the rear driveshaft and bolts. Tighten to 83 ft. lbs. (112 Nm).

Install the shift cable and bracket. Tighten to 30 ft. lbs. (40 Nm).



Use the following guidelines for installing 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.

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 up shifts (either soft or firm) and that this is a temporary condition and will eventually return to normal operating condition.


Connect the battery ground cable.

Position the fan shroud and install the bolts.

Carry out the fluid level check.

Verify that the shift cable is correctly adjusted. Check the operation of the transmission and inspect for leaks.





Before servicing the vehicle, refer to the -Precautions- section.

NOTE
When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy.


Disconnect the battery ground cable.

Remove the fan shroud bolts. Do not remove the fan shroud.

Raise and support the vehicle.

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

Remove the 2 right side heat shield bolts and position the shield aside.

Disconnect the 2 heated oxygen sensor electrical connectors.

Disconnect the 2 catalyst monitor sensor electrical connectors.

Remove the right side heat shield bolts.

Remove the right side heat shield bolt and remove the heat shield.

Remove the left side heat shield bolt.

Remove the 2 nuts and the plastic shield on the right side of the crossmember near the fuel tank.

Remove the 4 upper crossmember bolts (2 on each side).

Remove the bolts, springs, flag nuts and separate the muffler from the converter. Discard the gasket. Discard the flag nuts.

Remove the 4 converter-to-manifold nuts.

Remove the jack stand and lower the converter assembly with the heat shield.

CAUTION
Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.


Install a suitable jack under the transmission.

Remove the right side crossmember bolts.

Remove the left side crossmember bolts.

Remove the 2 bolts on the bracket and position aside.

Remove the transmission support insulator nuts and remove the crossmember.

NOTE
This step may require an assistant.


Remove the transmission mounted exhaust hanger and the 3-way converter assembly.

Remove the shift cable and bracket and position out of PARK.

Index-mark the location of the rear flange and pinion flange. Remove the 4 bolts. Remove the rear driveshaft pinion flange bolts.

NOTE
Do not use a hammer.


Remove the driveshaft flange from the pinion flange, using a pry bar.

Index-mark the driveshaft and the extension housing. Remove the driveshaft from the vehicle.

Remove the electrical connector cover.

Remove the starter wire and positive battery cable.

Remove the starter motor bolts and starter.

Remove the flexplate cover.

Remove the access cover.

NOTE
Make an identifying mark on the nut, stud and flexplate to allow for correct installation.


Remove the 4 torque converter nuts.

Lower the transmission to gain access to the sensor connectors and the transmission bolts.

Disconnect the right side catalyst monitor connector and the fuel lines from the bracket.

Disconnect the right side heated oxygen sensor from the transmission.

Disconnect the left side heated oxygen sensor and the harness clip from the transmission.

Disconnect the left side catalyst monitor connector from the transmission.

Move the rubber boot back to gain access to the connector. Disconnect the digital Transmission Range (TR) sensor connector.

Disconnect the Turbine Shaft Speed (TSS) sensor, Output Shaft Speed (OSS) sensor and Intermediate Shaft Speed (ISS) sensor electrical connectors.

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


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

Disconnect the harness retainers.

WARNING
Do not damage the cooler tubes.


Disconnect the transmission cooler tubes.

Remove the front crossmember.

Remove the 7 engine-to-transmission retaining bolts.

Lower the transmission assembly from the vehicle.

Install special tool 307-346 to hold the torque converter.

Carry out the transmission fluid cooler back flushing and cleaning if the transmission is being overhauled or installing a new or remanufactured transmission.



To install

CAUTION
Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.


Secure the transmission to the transmission jack with a safety chain.

NOTE
Rotate the torque converter so the orange or green paint daub is in the 12 o'clock position.


Raise and position the transmission to the back of the engine.

Install the 7 engine-to-transmission retaining bolts. Tighten to 35 ft. lbs. (48 Nm).

Install the 4 torque converter nuts. Tighten to 28 ft. lbs. (38 Nm).

Install the access cover.

Install the flexplate cover. Tighten to 25 ft. lbs. (34 Nm).

Install the starter. Tighten to 18 ft. lbs. (24 Nm).

Install the starter motor electrical connectors. Tighten to 115 inch lbs. (13 Nm).

Install the starter motor electrical connector cover.

Install the front crossmember. Tighten to 62 ft. lbs. (70 Nm).

WARNING
Use care not to bend or force the cooler tubes otherwise damage to the cooler tubes and the transmission can result.


Install the transmission fluid cooler tubes. Tighten to 22 ft. lbs. (30 Nm).

Connect the digital Transmission Range (TR) sensor connector. Move the rubber boot back over the connector.

Connect the left side Heated Oxygen Sensor (HO 2 S) to the transmission and install the wire harness retainer. Position the wire harness and install the retainers.

WARNING
Damage will occur to the solenoid body assembly if the screw is tightened above the specification.


NOTE
Always install new O-ring seals on the vehicle harness connector.


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


NOTE
Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.


Install and lubricate new O-ring seals on the transmission connector and connect the connector. Tighten to 44 inch lbs. (5 Nm).

Connect the left side catalyst monitor connector to the transmission.

Connect the right side Heated Oxygen Sensor (HO 2 S) to the transmission.

Connect the fuel lines and the right side catalyst monitor connector to the bracket.

Connect the Turbine Shaft Speed (TSS) sensor, Output Shaft Speed (OSS) sensor and Intermediate Shaft Speed (ISS) sensor electrical connectors.

NOTE
This step may require an assistant.


Position the catalytic converter assembly with heat shield and loosely install the 4 converter-to-manifold nuts.

Install the rear transmission mount bolts. Tighten to 66 ft. lbs. (90 Nm).

Connect the 2 heated oxygen sensor electrical connectors.

Connect the 2 catalyst monitor sensor electrical connectors.

Position the crossmember in place and loosely install the 2 nuts to hold up the crossmember.

NOTE
Using a transmission jack, raise the crossmember into place.


Install the right side crossmember bolts. Tighten to 52 ft. lbs. (70 Nm).

Install the left side crossmember bolts. Tighten to 52 ft. lbs. (70 Nm).

Remove the transmission jack.

Install the 4 upper crossmember bolts (2 on each side). Tighten to 52 ft. lbs. (70 Nm).

Tighten the rear transmission mount nuts. Tighten to 66 ft. lbs. (90 Nm).

Install the cable bracket and 2 bolts. Tighten to 30 ft. lbs. (40 Nm).

Install the heat shield bolts. Tighten to 15 ft. lbs. (20 Nm).

Install the right side heat shield and 2 bolts. Tighten to 15 ft. lbs. (20 Nm).

Install the left side heat shield bolts. Tighten to 15 ft. lbs. (20 Nm).

Install the plastic shield on the right side of the crossmember near the fuel tank. Tighten to 80 inch lbs. (9 Nm).

Tighten the 4 converter-to-manifold nuts. Tighten to 30 ft. lbs. (40 Nm).

Using a new gasket install the converter-to-muffler pipe. Install the bolts, springs and flag nuts. Tighten to 30 ft. lbs. (40 Nm).

Align the marks made during removal. Install the front portion of the driveshaft into the transmission.

WARNING
If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with Threadlock and Sealer TA-25 or equivalent meeting Ford specification WSK-M2G351-A5.


WARNING
The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in a cross pattern as shown.


Align the marks made during removal. Install the rear driveshaft and bolts. Tighten to 83 ft. lbs. (112 Nm).

Install the shift cable and bracket. Tighten to 30 ft. lbs. (40 Nm).

Use the following guidelines for installing 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.

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 up shifts (either soft or firm) and that this is a temporary condition and will eventually return to normal operating condition.




Connect the battery ground cable.

Position the fan shroud and install the bolts.

Carry out the fluid level check.

Verify that the shift cable is correctly adjusted.

Check the operation of the transmission and inspect for leaks.



Before servicing the vehicle, refer to the -Precautions- section.

NOTE
When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy.


Disconnect the battery ground cable.

Remove the fan shroud bolts. Do not remove the fan shroud.

Raise and support the vehicle.

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

Remove the 2 right heat shield bolts and position the right heat shield aside.

Disconnect the 2 heated oxygen sensor electrical connectors.

Disconnect the 2 catalyst monitor sensor electrical connectors.

Remove the right heat shield bolts.

Remove the right heat shield bolt and remove the heat shield.

Remove the left heat shield bolt.

Remove the plastic shield on the right side of the crossmember near the fuel tank.

Remove the 2 upper crossmember bolts (2 on each side).

Remove the bolts, springs, flag nuts and separate the muffler from the converter. Discard the gasket.

Discard the flag nuts.

Remove the 4 converter-to-manifold nuts.

Install a suitable jack stand under the transfer case.

Remove the right side crossmember bolts.

Remove the left side crossmember bolts.

Remove the transmission support insulator nuts and remove the crossmember.

NOTE
This step may require an assistant.


Remove the transmission mounted exhaust hanger and the 3-way converter system.

Remove the shift cable and bracket.

Position the manual lever out of park.

Index-mark the front axle pinion flange and the front driveshaft.

Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.

Remove and discard the bolts and washers.

Remove and discard the bolts and universal joint retainers.

WARNING
Always disconnect the front driveshaft from the transfer case 1st. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.


WARNING
Tape the bearing cups to the driveshaft to prevent them from falling off of the spider.


NOTE
The front driveshaft CV-joint is not repairable.


Remove the driveshaft.

Mark the location of the flanges. Remove the rear driveshaft bolts.

NOTE
Do not use a hammer.


Remove the driveshaft from the flange using a pry bar.

4.6L engine

Remove the electrical connector cover.

Remove the starter wire and the positive battery cable.

Remove the starter motor bolts and starter.

Remove the flexplate cover.

Remove the access cover.

NOTE
Make an identifying mark on the nut, stud and flexplate to allow for correct installation.


Remove the 4 torque converter nuts.



4.0L engine

Remove the starter and position off to the side.

NOTE
Make an identifying mark on the nut, stud and flexplate to allow for correct installation.


Remove the 4 torque converter nuts.

Remove the lower transmission retaining bolts.



All vehicles

Lower the transmission to gain access to the sensor connectors and the transmission bolts.

Disconnect the right catalyst monitor connector and the fuel lines from the bracket.

Disconnect the right heated oxygen sensor from the transmission.

If equipped, disconnect the shift motor electrical connector.

Disconnect the left heated oxygen sensor and the harness clip from the transmission.

Disconnect the left catalyst monitor connector from the transmission.

Move the rubber boot back to gain access to the connector.

Disconnect the digital Transmission Range (TR) sensor connector.

Disconnect the Turbine Shaft Speed (TSS) sensor, Output Shaft Speed (OSS) sensor and Intermediate Shaft Speed (ISS) sensor electrical connectors.

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


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

Disconnect the harness retainers.

WARNING
Do not damage the cooler tubes. Hold the transmission case fittings with a wrench.


Disconnect the transmission cooler tubes.

CAUTION
Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.


Support the transmission with a transmission jack.

Remove the jack stand from under the transfer case.

Remove the engine-to-transmission retaining bolts.

Lower the transmission and transfer case as an assembly from the vehicle.

Install a converter holding tool.

NOTE
If the transmission is being serviced, the transfer case will need to be removed.


Remove the transfer case from the back of the transmission.

Carry out the transmission fluid cooler back flushing and cleaning if the transmission is being overhauled or installing a new or remanufactured transmission.





To install:

CAUTION
Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.


Secure the transmission to the transmission jack with a safety chain.

NOTE
Rotate the torque converter so that the torque converter paint mark is in the 12 o'clock position.


Raise and position the transmission to the back of the engine.

On 2005 4.6L engine, perform the following:

Torque the 7 engine-to-transmission retaining bolts: 35 ft. lbs. (48 Nm).

Torque the 4 torque converter nuts: 28 ft. lbs. (38 Nm).

Install the access cover.

Install the flexplate cover to 25 ft. lbs. (34 Nm).

Install the starter to 18 ft. lbs. (24 Nm).

Install the starter motor electrical connectors. Tighten the cable to 115 inch lbs. (13 Nm). Tighten the wire to 53 inch lbs. (6 Nm).

Install the starter motor electrical connector cover.

Install the front crossmember bolts to 52 ft. lbs. (70 Nm).



On 2005 4.0L engine, perform the following:

Position the fuel line bracket in place and install the 6 retaining bolts. Tighten to 35 ft. lbs. (48 Nm).

Install the 4 torque converter nuts. Tighten to 28 ft. lbs. (38 Nm).

Install the starter motor. Tighten to 18 ft. lbs. (25 Nm).

Install the lower transmission retaining bolts. Tighten to 35 ft. lbs. (48 Nm).



All vehicles:

WARNING
Use care not to bend or force the cooler tubes otherwise damage to the cooler tubes and the transmission can result.


Install the transmission fluid cooler tubes. Tighten to 22 ft. lbs. (30 Nm).

Connect the digital Transmission Range (TR) sensor connector. Move the rubber boot back over the connector.

Connect the left Heated Oxygen Sensor (HO 2 S) to the transmission and install the wire harness retainer. Position the wire harness and install the retainers.

WARNING
Damage will occur to the solenoid body assembly if the screw is tightened above the specification.


NOTE
Always install new O-ring seals on the vehicle harness connector.


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


NOTE
Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.


Install and lubricate new O-ring seals on the transmission connector and connect the connector. Tighten to 44 inch lbs. (5 Nm).

Connect the left catalyst monitor connector to the transmission.

Connect the right Heated Oxygen Sensor (HO 2 S) to the transmission.

Connect the fuel lines and the right catalyst monitor connector to the bracket.

Connect the Turbine Shaft Speed (TSS) sensor, Output Shaft Speed (OSS) sensor, and Intermediate Shaft Speed (ISS) sensor electrical connectors.

NOTE
This step may require an assistant.


Position the catalytic converter assembly with heat shield and loosely install the 4 converter-to-manifold nuts.

Install the rear transmission mount bolts. Tighten to 66 ft. lbs. (90 Nm).

Connect the 2 heated oxygen sensor electrical connectors.

Connect the 2 catalyst monitor sensor electrical connectors.

Position the crossmember in place and loosely install the 2 nuts to hold up the crossmember.

NOTE
Using a transmission jack, raise the crossmember into place.


Install the right side crossmember bolts. Tighten to 52 ft. lbs. (70 Nm).

Install the left side crossmember bolts. Tighten to 52 ft. lbs. (70 Nm).

Remove the transmission jack.

Install the 2 upper crossmember bolts (2 on each side). Tighten to 52 ft. lbs. (70 Nm).

Tighten the rear transmission mount nuts. Tighten to 66 ft. lbs. (90 Nm).

Install the cable bracket and 2 bolts. Tighten to 30 ft. lbs. (40 Nm).

Install the heat shield bolts. Tighten to 15 ft. lbs. (20 Nm).

Install the right heat shield and 3 bolts. Tighten to 15 ft. lbs. (20 Nm).

Install the left heat shield bolts. Tighten to 15 ft. lbs. (20 Nm).

Install the plastic shield on the right side of the crossmember near the fuel tank. Tighten to 80 inch lbs. (9 Nm).

Tighten the 4 converter-to-manifold nuts. Tighten to 30 ft. lbs. (40 Nm).

Using a new gasket install the converter-to-muffler pipe. Install the bolts, springs and flag nuts. Tighten to 30 ft. lbs. (40 Nm).

Align the marks made during removal. Install the front portion of the driveshaft into the transmission.

WARNING
If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with Threadlock and Sealer TA-25 or equivalent meeting Ford specification WSK-M2G351-A5.


WARNING
The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in a cross pattern as shown.




image

Fig. Rear driveshaft flange torque sequence-2005 Explorer and Mountaineer

Align the marks made during removal. Install the rear driveshaft and bolts. Tighten to 83 ft. lbs. (112 Nm).

Install the shift cable and bracket. Tighten to 30 ft. lbs. (40 Nm).

Use the following guidelines for installing 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.

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 up shifts (either soft or firm) and that this is a temporary condition and will eventually return to normal operating condition.

Connect the battery ground cable.
Position the fan shroud and install the bolts.
Carry out the fluid level check.
Verify that the shift cable is correctly adjusted. Check the operation of the transmission and inspect for leaks.

The details will help you.
Thanks.

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