Thursday, March 8, 2012

Ford Manual Transmission Replacing?

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

Transmission Removal & Installation Instructions are as follows :-----


  1. Before servicing the vehicle, refer to the Precautions section.
  2. Drain the transmission fluid.
  3. Place the transmission in Neutral .
  4. Remove or disconnect the following:

    Negative battery cable
    Gearshift lever assembly from the control housing
  5. On 2WD vehicles, matchmark the driveshaft to the rear axle flange. Position a drain pan under the rear of the transmission. Remove the driveshaft-to-rear axle flange fasteners and pull the driveshaft rearward to disengage it from the transmission.

    Heated Oxygen (HO 2 S) sensor
    Back-up lamp switch electrical connector
    Fan shroud
    Clutch hydraulic line at the clutch housing
    Speedometer from the transfer case/extension housing and place a wood block on a service jack and position the jack under the engine oil pan
    Transfer case on 4WD vehicles
    Starter
  6. Position a transmission jack under the transmission.

    Transmission-to-engine retaining bolts and washers
    Transmission mount and damper to the crossmember
    Crossmember and lower the engine jack slightly to angle the transmission assembly. Work the clutch housing off the locating dowels and slide the clutch housing and the transmission rearward until the input shaft clears the clutch disc
    Exhaust inlet cross over pipe
    Transmission from the vehicle
To install:
  1. Check that the mating surfaces of the clutch housing, engine rear and dowel holes are free of burrs, dirt and paint.
  2. Place the transmission on the transmission jack. Position the transmission under the vehicle, then raise it into position. Align the input shaft splines with the clutch disc splines and work the transmission forward onto the locating dowels.
  3. Install or connect the following:

    Transmission-to-engine retaining bolts and washers. Tighten the retaining bolts to 30-41 ft. lbs. (40-55 Nm).
    Exhaust inlet cross over pipe and remove the transmission jack
    Right side transmission mount. Torque the bolt to 81 ft. lbs. (110 Nm).
    Rear crossmember. Torque the bolts to 53 ft. lbs. (72 Nm).
    Starter motor and tighten the attaching nuts
    Transfer case on 4WD vehicles. Torque the bolts to 87 ft. lbs. (119 Nm).
    Rear driveshaft
    Starter motor, back-up lamp switch connectors
    Hydraulic clutch line and bleed the system
    Speedometer cable
    Gearshift lever assembly
    Negative battery cable
  4. Fill the transmission fluid to the proper level.
  5. Check for proper shifting and operation of the transmission.
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2. Disconnect the negative battery cable
    NOTE
    Do not remove the gearshift lever knob.
  3. Remove the screw and lift the console finish panel to access the gearshift lever nut. Remove the gearshift lever nut, then remove the upper gearshift lever and console finish panel as an assembly.
  4. Install the nut on the front of the lever, then tighten the nut to remove the eccentric stud out of the gearshift lever.
  5. Place the transmission in NEUTRAL.
  6. If the transmission is being disassembled, drain the transmission fluid.
  7. Remove or disconnect the following:

    Front support
    Starter
    Rear driveshaft and position it aside
    Transfer case
  8. Using a suitable high lift jack, support the transmission. Securely strap the jack to the transmission.
  9. Remove or disconnect the following:

    Right crossmember cover, then the four bolts
    left crossmember bolts
    Heat shields from the crossmember
    Nuts, then lower the crossmember from the vehicle
    Hydraulic line from the clutch slave cylinder
    Output shaft speed (OSS) sensor electrical connector
    Reverse lamp switch electrical connector
    Wiring harness brackets from the transmission, then disconnect the heated oxygen sensor (HO2S) electrical connectors
    The two rear three way catalytic converter (TWC) bolts
    Front TWC bolts and the TWC
    The eight transmission-to-engine bolts
    Transmission.
To install:
  1. Raise and position the transmission to the engine and clutch.
  2. Install the eight transmission-to-engine bolts. Torque the bolts to 44 ft. lbs. (50 Nm).
  3. Position the front three way catalytic converter (TWC) in the vehicle and install the bolts. Do not tighten the bolts at this time.
  4. Using a new gasket and nuts, install the two rear three way catalytic converter (TWC) bolts. Tighten the rear bolts, then the front bolts at this time. Tighten the bolts to 30 ft. lbs. (40 Nm).
  5. Install or connect the following:

    Heated oxygen sensor (HO2S) electrical connectors
    right and left crossmember bolts and the right crossmember cover. Torque the crossmember nuts to 46 ft. lbs. (63Nm).
    Transmission mount nuts. Torque the nuts to 72 ft. lbs. (98 Nm).
    Heat shields to the crossmember
    Wiring harness brackets and attach the wiring harness
    Front support
    Hydraulic line to the clutch slave cylinder
    Starter
    Transfer case
    Driveshaft
  6. Position the upper gearshift lever, the outer gearshift lever boot and console finish panel into the console, then install the nut.
  7. Connect the battery ground cable.
  8. Bleed the clutch hydraulic system.
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Disconnect the negative battery cable
    NOTE
    Do not remove the gearshift lever knob.
  3. Remove the screw and lift the console finish panel to access the gearshift lever nut. Remove the gearshift lever nut, then remove the upper gearshift lever and console finish panel as an assembly.
  4. Install the nut on the front of the lever, then tighten the nut to remove the eccentric stud out of the gearshift lever.
  5. place the transmission in NEUTRAL.
  6. If the transmission is being disassembled, drain the transmission fluid.
  7. Remove or disconnect the following:

    Front support
    Starter
    Rear driveshaft and position it aside
    Transfer case
  8. Using a suitable high lift jack, support the transmission. Securely strap the jack to the transmission.
  9. Remove or disconnect the following:

    RH crossmember cover, then the four bolts
    LH crossmember bolts
    Heat shields from the crossmember
    Nuts, then lower the crossmember from the vehicle
    Hydraulic line from the clutch slave cylinder
    Output shaft speed (OSS) sensor electrical connector
    Reverse lamp switch electrical connector
    Wiring harness brackets from the transmission, then disconnect the heated oxygen sensor (HO2S) electrical connectors
    The two rear three way catalytic converter (TWC) bolts
    Front TWC bolts and the TWC
    The eight transmission-to-engine bolts
    Transmission.
To install:
  1. Raise and position the transmission to the engine and clutch.
  2. Install the eight transmission-to-engine bolts. Torque the bolts to 44 ft. lbs. (50Nm).
  3. Position the front three way catalytic converter (TWC) in the vehicle and install the bolts. Do not tighten the bolts at this time.
  4. Using a new gasket and nuts, install the two rear three way catalytic converter (TWC) bolts. Tighten the rear bolts, then the front bolts at this time. Tighten the bolts to 30 ft. lbs. (40Nm).
  5. Install or connect the following:

    Heated oxygen sensor (HO2S) electrical connectors
    RH and LH crossmember bolts and the RH crossmember cover. Torque the crossmember nuts to 46 ft. lbs. (63Nm).
    Transmission mount nuts. Torque the nuts to 72 ft. lbs. (98Nm).
    Heat shields to the crossmember
    Wiring harness brackets and attach the wiring harness
    Front support
    Hydraulic line to the clutch slave cylinder
    Starter
    Transfer case
    Driveshaft
  6. Position the upper gearshift lever, the outer gearshift lever boot and console finish panel into the console, then install the nut.
  7. Connect the battery ground cable.
  8. Bleed the clutch hydraulic system.


The details are as follows:----



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