Thursday, March 8, 2012

Ford Explorer Transmission A340F Removal and Installation Procedure?


The details are for ford explorer Transmission replacement.

It will also work for
Lincoln Aviator, Ford Explorer, Exp Sport, Exp Sport-Trac, Mercury Mountaineer 2000-2005

A340f

  1. 4-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 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 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.
    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 bolt and converter assembly. If required, remove the 2nd bolt and moun
    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 first. 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.

    Mark the location of the flanges. Remove the 4 bolts.
    Remove the rear driveshaft bolts.

    NOTE
    Do not use a hammer.
    Remove the driveshaft from the flange using a pry bar.
    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 cove
    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 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 4 front crossmember bolts and the crossmember.
    Remove the 7 engine-to-transmission retaining bolts.
    Lower the transmission and transfer case as an assembly from the vehicle.
    Install special tool 307-346 to hold the converter.

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

    Click image to see an enlarged view
    Fig. Torque converter holding tool
  2. 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
  1. Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.

    If removed, install the transfer case to the back of the transmission, install the bracket and connect the vent hose. Tighten to 30 ft. lbs. (41 Nm)

    Remove the special tool.
    CAUTION
    Make sure that the transmission and transfer case assembly are secured to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.


    NOTE



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

    Raise and position the transmission and transfer case 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 and the 4 bolts (2 on each side). Tighten to 52 ft. lbs. (70 Nm).

    Install a jack stand under the transfer case.

    Remove the transmission jack from under the transmission.
  2. 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.
  3. 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.
  4. 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.
  5. NOTE
    This step may require an assistant.
  6. 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. 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 jack stand. Install the 4 upper crossmember bolts (2 on each side). Tighten to 52 ft. lbs. (70 Nm). Tighten the rear transmission mount nuts to 66 ft. lbs. (90 Nm). Install the right heat shield and 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 and the heat shield. Install the bolts, springs and flag nuts. Tighten to 30 ft. lbs. (40 Nm). If equipped, connect the shift motor electrical connector.
  7. WARNING
    The can (domed CV-joint housing cover) is pressed into the CV-joint housing at the factory. When housed correctly, the can will appear as shown in the illustration, top box. Do not reseat the can in the CV-joint housing if the can's flange is above the CV-joint housings shown in the illustration, bottom box.



    Click image to see an enlarged view
    Fig. Proper can installation-2004-05 4WD models
  8. Install a new driveshaft. Verify that the can flange is housed correctly in the CV-joint housing as shown in the illustration, top box. Install a new driveshaft if the can flange is not housed correctly. WARNING Always connect the front driveshaft to the axle first. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear. Align the index marks. Install the driveshaft. WARNING Tighten the bolts evenly in a cross pattern or damage will occur to the CV-joint. NOTE Install new washers and bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.

  9. Click image to see an enlarged view
    Fig. Driveshaft joint torque sequence-2004-05 4WD Aviator models
  10. Install the new washers and bolts. Tighten the bolts evenly in a cross pattern as shown. Tighten to 22 ft. lbs. (30 Nm).
  11. Verify that the CV-joint has seated squarely in the transfer case flange.
    • Check that the space between the end of the CV-joint cap and the end of the transfer case flange is equal from the top to the bottom of the 2 components.
    • Rotate the driveshaft 1 / 4 turn.
    • Check that the space between the end of the CV-joint cap and the end of the transfer case flange is equal from the top to the bottom of the 2 components.
    • Repeat this procedure several times.
    • If the space if not equal at any point in the attachment, remove and reinstall the driveshaft as described in this procedure.
  12. NOTE
    Install new universal joint retainers and bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.
  13. Align the index marks and install the new universal joint retainer and bolts. Tighten to 13 ft lbs. (18 Nm).
    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.
  14. Install the rear driveshaft and the 8 bolts. Tighten to 83 ft. lbs. (112 Nm). Install the shift cable and bracket. Tighten to 30 ft. lbs. (40 Nm).
  15. 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.
  16. 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.
  1. 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.
  2. 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. NOTE The pinion flange is shown, transfer case flange is similar. 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. For 4.6L engines, perform the following: 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. For 4.0L engines, perform the following: 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. For 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 jackstand from under the transfer case. 4.6L engine: Remove the 4 front crossmember bolts and the crossmember. Remove the 7 engine-to-transmission retaining bolts. 4.0L engine: Remove the 6 engine-to-transmission retaining bolts and position the fuel line bracket aside. 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 backflushing 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. If removed, install the transfer case to the back of the transmission, install the bracket and connect the vent hose. Tighten to 30 ft. lbs. (41 Nm) Remove the special tool. CAUTION Make sure that the transmission and transfer case assembly are secured to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury. NOTE Rotate the torque converter so that the torque converter paint mark is in the 12 o'clock position. Raise and position the transmission and transfer case 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 26 ft. lbs. (35 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. NOTE right side shown, left side similar. Install the front crossmember and the 4 bolts (2 on each side). Tighten to 52 ft. lbs. (70 Nm). 4.0L engine: Position the fuel line bracket in place and install the 6 engine-to-transmission retaining bolts. Tighten to 35 ft. lbs. (48 Nm). Install the 4 torque converter nuts. Tighten to 26 ft. lbs. (35 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: Install a jackstand under the transfer case. Remove the transmission jack from under the transmission. 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. Position the rear transmission mount and exhaust hanger. Install the rear 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. 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 jackstand. 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 right heat shield and 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 and the heat shield. Install the bolts, springs and flag nuts. Tighten to 30 ft. lbs. (40 Nm). If equipped, connect the shift motor electrical connector. WARNING The can (domed CV-joint housing cover) is pressed into the CV-joint housing at the factory. When housed correctly, the can will appear as shown in the cut-away illustration, top box. Do not reseat the can in the CV-joint housing if the can's flange is above the CV-joint housings shown in the cut-away illustration, bottom box. Install a new driveshaft. Verify that the can flange is housed correctly in the CV-joint housing as shown in the cut-away illustration, top box. Install a new driveshaft if the can flange is not housed correctly. WARNING Always connect the front driveshaft to the axle 1st. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear. NOTE Align the index marks. Install the driveshaft. WARNING Tighten the bolts evenly in a cross pattern or damage will occur to the CV-joint. NOTE Install new washers and bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer. Install the new washers and bolts. Tighten the bolts evenly in a cross pattern. Tighten to 22 ft. lbs. (30 Nm). Verify that the CV-joint has seated squarely in the transfer case flange. Check that the space between the end of the CV-joint cap and the end of the transfer case flange is equal from the top to the bottom of the 2 components. Rotate the driveshaft 1 / 4 turn. Check that the space between the end of the CV-joint cap and the end of the transfer case flange is equal from the top to the bottom of the 2 components. Repeat this procedure several times. If the space if not equal at any point in the attachment, remove and reinstall the driveshaft as described in this procedure. NOTE Install new universal joint retainers and bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer. Install the new universal joint retainer and bolts. Tighten to 13 ft lbs. (18 Nm). 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. Install the rear driveshaft and the 8 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 upshifts (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 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. 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 bolt and converter assembly. If required, remove the 2nd bolt and mount. 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 first. 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. Mark the location of the flanges. Remove the 4 bolts. Remove the rear driveshaft bolts. NOTE Do not use a hammer. Remove the driveshaft from the flange using a pry bar. 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. 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 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 4 front crossmember bolts and the crossmember. Remove the 7 engine-to-transmission retaining bolts. Lower the transmission and transfer case as an assembly from the vehicle. Install special tool 307-346 to hold the converter. NOTE If the transmission is being serviced, the transfer case will need to be removed.

  1. Click image to see an enlarged view
    Fig. Torque converter holding tool
  2. Remove the transfer case from the back of the transmission.
  3. 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.

  1. If removed, install the transfer case to the back of the transmission, install the bracket and connect the vent hose. Tighten to 30 ft. lbs. (41 Nm)
  2. Remove the special tool.
    CAUTION
    Make sure that the transmission and transfer case assembly are secured to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.


    NOTE
    Rotate the torque converter so the orange or green paint daub is in the 12 o'clock position.
  3. Raise and position the transmission and transfer case to the back of the engine.
  4. Install the 7 engine-to-transmission retaining bolts. Tighten to 35 ft. lbs. (48 Nm).
  5. Install the 4 torque converter nuts. Tighten to 28 ft. lbs. (38 Nm).
  6. Install the access cover.
  7. Install the flexplate cover. Tighten to 25 ft. lbs. (34 Nm).
  8. Install the starter. Tighten to 18 ft. lbs. (24 Nm).
  9. Install the starter motor electrical connectors. Tighten to 115 inch lbs. (13 Nm).
  10. Install the starter motor electrical connector cover.
  11. Install the front crossmember and the 4 bolts (2 on each side). Tighten to 52 ft. lbs. (70 Nm).
  12. Install a jack stand under the transfer case.
  13. Remove the transmission jack from under the transmission.
    WARNING
    Use care not to bend or force the cooler tubes otherwise damage to the cooler tubes and the transmission can result.
  14. Install the transmission fluid cooler tubes. Tighten to 22 ft. lbs. (30 Nm).
  15. Connect the digital Transmission Range (TR) sensor connector. Move the rubber boot back over the connector.
  16. 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.
  17. Install and lubricate new O-ring seals on the transmission connector and connect the connector. Tighten to 44 inch lbs. (5 Nm).
  18. Connect the left catalyst monitor connector to the transmission.
  19. Connect the right Heated Oxygen Sensor (HO 2 S) to the transmission.
  20. Connect the fuel lines and the right catalyst monitor connector to the bracket.
  21. 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.
  22. Position the catalytic converter assembly with heat shield and loosely install the 4 converter-to-manifold nuts.
  23. Install the rear transmission mount bolts. Tighten to 66 ft. lbs. (90 Nm).
  24. Connect the 2 heated oxygen sensor electrical connectors.
  25. Connect the 2 catalyst monitor sensor electrical connectors.
  26. Position the crossmember in place and loosely install the 2 nuts to hold up the crossmember.
  27. Install the right side crossmember bolts. Tighten to 52 ft. lbs. (70 Nm).
  28. Install the left side crossmember bolts. Tighten to 52 ft. lbs. (70 Nm).
  29. Remove the jack stand.
  30. Install the 4 upper crossmember bolts (2 on each side). Tighten to 52 ft. lbs. (70 Nm).
  31. Tighten the rear transmission mount nuts to 66 ft. lbs. (90 Nm).
  32. Install the right heat shield and bolts. Tighten to 15 ft. lbs. (20 Nm).
  33. Install the left heat shield bolts. Tighten to 15 ft. lbs. (20 Nm).
  34. Install the plastic shield on the right side of the crossmember near the fuel tank. Tighten to 80 inch lbs. (9 Nm).
  35. Tighten the 4 converter-to-manifold nuts. Tighten to 30 ft. lbs. (40 Nm).
  36. Using a new gasket, install the converter-to-muffler pipe and the heat shield. Install the bolts, springs and flag nuts. Tighten to 30 ft. lbs. (40 Nm).
  37. If equipped, connect the shift motor electrical connector.
    WARNING
    The can (domed CV-joint housing cover) is pressed into the CV-joint housing at the factory. When housed correctly, the can will appear as shown in the illustration, top box. Do not reseat the can in the CV-joint housing if the can's flange is above the CV-joint housings shown in the illustration, bottom box.



    Click image to see an enlarged view
    Fig. Proper can installation-2005 Aviator 4WD models
  38. Install a new driveshaft.
  39. Verify that the can flange is housed correctly in the CV-joint housing as shown in the illustration, top box. Install a new driveshaft if the can flange is not housed correctly.
    WARNING
    Always connect the front driveshaft to the axle first. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.
  40. Align the index marks. Install the driveshaft.
    WARNING
    Tighten the bolts evenly in a cross pattern or damage will occur to the CV-joint.


    NOTE
    Install new washers and bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.



    Click image to see an enlarged view
    Fig. Driveshaft joint torque sequence-2005 Aviator 4WD Aviator models
  41. Install the new washers and bolts. Tighten the bolts evenly in a cross pattern as shown. Tighten to 22 ft. lbs. (30 Nm).
  42. Verify that the CV-joint has seated squarely in the transfer case flange.
    1. Check that the space between the end of the CV-joint cap and the end of the transfer case flange is equal from the top to the bottom of the 2 components.
    2. Rotate the driveshaft 1 / 4 turn.
    3. Check that the space between the end of the CV-joint cap and the end of the transfer case flange is equal from the top to the bottom of the 2 components.
    4. Repeat this procedure several times.
    5. If the space if not equal at any point in the attachment, remove and reinstall the driveshaft as described in this procedure.
      NOTE
      Install new universal joint retainers and bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.
  43. Align the index marks and install the new universal joint retainer and bolts. Tighten to 13 ft lbs. (18 Nm).
    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.
  44. Install the rear driveshaft and the 8 bolts. Tighten to 83 ft. lbs. (112 Nm).
  45. Install the shift cable and bracket. Tighten to 30 ft. lbs. (40 Nm).
  46. Use the following guidelines for installing the in-line transmission fluid filter:
    1. If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a new in-line fluid filter.
    2. 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.
    3. If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter kit.
    4. If installing a new or a Ford-authorized remanufactured transmission, install the in-line transmission fluid filter that is supplied.
    5. 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.
  47. Connect the battery ground cable.
  48. Position the fan shroud and install the bolts.
  49. Carry out the fluid level check.
  50. Verify that the shift cable is correctly adjusted.
  51. Check the operation of the transmission and inspect for leaks.
  1. 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.
  2. Disconnect the battery ground cable.
  3. Remove the fan shroud bolts. Do not remove the fan shroud.
  4. Raise and support the vehicle.
  5. If transmission disassembly or installation of new transmission is necessary, drain the transmission fluid. Install the drain plug when finished.
  6. Remove the 2 right heat shield bolts and position the right heat shield aside.
  7. Disconnect the 2 heated oxygen sensor electrical connectors.
  8. Disconnect the 2 catalyst monitor sensor electrical connectors.
  9. Remove the right heat shield bolts.
  10. Remove the right heat shield bolt and remove the heat shield.
  11. Remove the left heat shield bolt.
  12. Remove the plastic shield on the right side of the crossmember near the fuel tank.
  13. Remove the 2 upper crossmember bolts (2 on each side).
  14. Remove the bolts, springs, flag nuts and separate the muffler from the converter. Discard the gasket. Discard the flag nuts.
  15. Remove the 4 converter-to-manifold nuts.
  16. Install a suitable jack stand under the transfer case.
  17. Remove the right side crossmember bolts.
  18. Remove the left side crossmember bolts.
  19. Remove the transmission support insulator nuts and remove the crossmember.
    NOTE
    This step may require an assistant.
  20. Remove the transmission mounted exhaust hanger and the 3-way converter system.
  21. Remove the shift cable and bracket. Position the manual lever out of park.
  22. Index-mark the front axle pinion flange and the front driveshaft.
  23. Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.
  24. Remove and discard the bolts and washers.
  25. 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.
  26. Remove the driveshaft.
    NOTE
    The pinion flange is shown, transfer case flange is similar.
  27. Mark the location of the flanges. Remove the rear driveshaft bolts.
    NOTE
    Do not use a hammer.
  28. Remove the driveshaft from the flange using a pry bar.
  29. For 4.6L engine, perform the following:
    1. Remove the electrical connector cover.
    2. Remove the starter wire and the positive battery cable.
    3. Remove the starter motor bolts and starter.
    4. Remove the flexplate cover.
    5. Remove the access cover.
      NOTE
      Make an identifying mark on the nut, stud and flexplate to allow for correct installation.
    6. Remove the 4 torque converter nuts.
  30. For 4.0L engine, perform the following:
    1. 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.
    2. Remove the 4 torque converter nuts.
    3. Remove the lower transmission retaining bolts.
  31. For all vehicles:
    1. Lower the transmission to gain access to the sensor connectors and the transmission bolts.
    2. Disconnect the right catalyst monitor connector and the fuel lines from the bracket.
    3. Disconnect the right heated oxygen sensor from the transmission.
    4. If equipped, disconnect the shift motor electrical connector.
    5. Disconnect the left heated oxygen sensor and the harness clip from the transmission.
    6. Disconnect the left catalyst monitor connector from the transmission. Move the rubber boot back to gain access to the connector.
    7. Disconnect the digital Transmission Range (TR) sensor connector.
    8. 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.
    9. Remove the screw from the solenoid body connector and disconnect the connector.
    10. Disconnect the harness retainers.
      WARNING
      Do not damage the cooler tubes. Hold the transmission case fittings with a wrench.
    11. 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.
    12. Support the transmission with a transmission jack.
    13. Remove the jackstand from under the transfer case.
  32. 4.6L engine:
    1. Remove the 4 front crossmember bolts and the crossmember.
    2. Remove the 7 engine-to-transmission retaining bolts.
  33. 4.0L engine:
    1. Remove the 6 engine-to-transmission retaining bolts and position the fuel line bracket aside.
  34. All vehicles:
    1. 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.
    2. Remove the transfer case from the back of the transmission.
    3. Carry out the transmission fluid cooler backflushing 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.

  1. If removed, install the transfer case to the back of the transmission, install the bracket and connect the vent hose. Tighten to 30 ft. lbs. (41 Nm)
  2. Remove the special tool.
    CAUTION
    Make sure that the transmission and transfer case assembly are secured to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.


    NOTE
    Rotate the torque converter so that the torque converter paint mark is in the 12 o'clock position.
  3. Raise and position the transmission and transfer case to the back of the engine.
  4. 4.6L engine:
    1. Install the 7 engine-to-transmission retaining bolts. Tighten to 35 ft. lbs. (48 Nm).
    2. Install the 4 torque converter nuts. Tighten to 26 ft. lbs. (35 Nm).
    3. Install the access cover.
    4. Install the flexplate cover. Tighten to 25 ft. lbs. (34 Nm).
    5. Install the starter. Tighten to 18 ft. lbs. (24 Nm).
    6. Install the starter motor electrical connectors. Tighten the cable to 115 inch lbs. (13 Nm). Tighten the wire to 53 inch lbs. (6 Nm).
    7. Install the starter motor electrical connector cover.
      NOTE
      right side shown, left side similar.
    8. Install the front crossmember and the 4 bolts (2 on each side). Tighten to 52 ft. lbs. (70 Nm).
  5. 4.0L engine:
    • Position the fuel line bracket in place and install the 6 engine-to-transmission retaining bolts. Tighten to 35 ft. lbs. (48 Nm).
    • Install the 4 torque converter nuts. Tighten to 26 ft. lbs. (35 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).
  6. All vehicles:
    • Install a jackstand under the transfer case.
    • Remove the transmission jack from under the transmission.

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.
    1. Install and lubricate new O-ring seals on the transmission connector and connect the connector. Tighten to 44 inch lbs. (5 Nm).
    2. Connect the left catalyst monitor connector to the transmission.
    3. Connect the right Heated Oxygen Sensor (HO 2 S) to the transmission.
    4. Connect the fuel lines and the right catalyst monitor connector to the bracket.
    5. 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.
    6. Position the catalytic converter assembly with heat shield and loosely install the 4 converter-to-manifold nuts.
    7. Position the rear transmission mount and exhaust hanger. Install the rear mount bolts. Tighten to 66 ft. lbs. (90 Nm).
    8. Connect the 2 heated oxygen sensor electrical connectors.
    9. Connect the 2 catalyst monitor sensor electrical connectors.
    10. Position the crossmember in place and loosely install the 2 nuts to hold up the crossmember.
    11. Install the right side crossmember bolts. Tighten to 52 ft. lbs. (70 Nm).
    12. Install the left side crossmember bolts. Tighten to 52 ft. lbs. (70 Nm).
    13. Remove the jackstand.
    14. Install the 2 upper crossmember bolts (2 on each side). Tighten to 52 ft. lbs. (70 Nm).
    15. Tighten the rear transmission mount nuts. Tighten to 66 ft. lbs. (90 Nm).
    16. Install the right heat shield and bolts. Tighten to 15 ft. lbs. (20 Nm).
    17. Install the left heat shield bolts. Tighten to 15 ft. lbs. (20 Nm).
    18. Install the plastic shield on the right side of the crossmember near the fuel tank. Tighten to 80 inch lbs. (9 Nm).
    19. Tighten the 4 converter-to-manifold nuts. Tighten to 30 ft. lbs. (40 Nm).
    20. Using a new gasket, install the converter-to-muffler pipe and the heat shield. Install the bolts, springs and flag nuts. Tighten to 30 ft. lbs. (40 Nm).
    21. If equipped, connect the shift motor electrical connector.
      WARNING
      The can (domed CV-joint housing cover) is pressed into the CV-joint housing at the factory. When housed correctly, the can will appear as shown in the cut-away illustration, top box. Do not reseat the can in the CV-joint housing if the can's flange is above the CV-joint housings shown in the cut-away illustration, bottom box. Install a new driveshaft.
    22. Verify that the can flange is housed correctly in the CV-joint housing as shown in the cut-away illustration, top box. Install a new driveshaft if the can flange is not housed correctly.
      WARNING
      Always connect the front driveshaft to the axle 1st. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.


      NOTE
      Align the index marks.
    23. Install the driveshaft.
      WARNING
      Tighten the bolts evenly in a cross pattern or damage will occur to the CV-joint.


      NOTE
      Install new washers and bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.
    24. Install the new washers and bolts. Tighten the bolts evenly in a cross pattern. Tighten to 22 ft. lbs. (30 Nm).
    25. Verify that the CV-joint has seated squarely in the transfer case flange.
    26. Check that the space between the end of the CV-joint cap and the end of the transfer case flange is equal from the top to the bottom of the 2 components.
    27. Rotate the driveshaft 1 / 4 turn.
    28. Check that the space between the end of the CV-joint cap and the end of the transfer case flange is equal from the top to the bottom of the 2 components.
    29. Repeat this procedure several times.
    30. If the space if not equal at any point in the attachment, remove and reinstall the driveshaft as described in this procedure.
      NOTE
      Install new universal joint retainers and bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.
    31. Install the new universal joint retainer and bolts. Tighten to 13 ft lbs. (18 Nm).
      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.
    32. Install the rear driveshaft and the 8 bolts. Tighten to 83 ft. lbs. (112 Nm).
    33. Install the shift cable and bracket. Tighten to 30 ft. lbs. (40 Nm).
  1. 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 upshifts (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.

    FOR MORE HELP GO TO: ---
    Car repair guide?
    http://technoanswers.blogspot.in/2012/03/car-repair-guide.html

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