Transmission - All Wheel Drive (AWD): Installation

1. 1.
   
   If removed, inspect the transmission mounted transmission fluid cooler tube backing rings and seals for damage and install new backing rings or seals if necessary. Lubricate the transmission mounted transmission fluid cooler tube seals with clean Motorcraft ®MERCON ® LV Automatic Transmission Fluid and install the backing rings and seals on the transmission mounted transmission fluid cooler tubes.

   Item	Service Part Number	Description
   1	7D285	Seal
   2	7J324	Backing ring

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1. 2.
   
   If removed, position the transmission fluid cooler thermal bypass valve and transmission mounted transmission fluid cooler tube assembly in place and install the nuts.
   • Tighten to 9 Nm (80 lb-in).

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1. 3.
   
   If removed, install new transmission mounted transmission fluid cooler tube bolts.
   • Tighten to 9 Nm (80 lb-in).

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1. 4.
   
   Lubricate the torque converter pilot hub with Multi-Purpose Grease.

NOTE: If the transmission is not positioned on the dowel pins, damage to the transmission may occur.
1. 5.
   If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.

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1. 6.
   
   Using 209-00152, support the transmission.

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1. 7.
   
   Position the transmission behind the engine and remove 307-346 T97T-7902-A.

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1. 8.
   
   Position the transmission on the dowel pins and install the lower torque converter housing bolts.

   1. 1.
      
      If equipped.
   • Tighten to 48 Nm (35 lb-ft).

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1. 9.
   
   Install the transmission support insulator bracket, the nuts and the bolt.
   • Tighten the bolt to 80 Nm (59 lb-ft).
   • Tighten the nuts to 63 Nm (46 lb-ft).

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1. 10.
   
   Remove 303-F070 and 303-1454.

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1. 11.
   
   Install the RH and LH cowl filler panels and retainers.

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1. 12.
   
   Remove 303-1245 from the LH cylinder head.

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1. 13.
   
   Install the transmission fluid cooler tubes in the transmission fluid cooler thermal bypass valve.

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1. 14.
   
   Install the secondary latches on the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.

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NOTE: Use only the specified bolts for the torque converter. Standard length fasteners may bottom out and damage the torque converter clutch apply surface.
1. 15.
   Install 3 new torque converter bolts (-W714722-).
   • Tighten to 55 Nm (41 lb-ft).
   • Install the first torque converter bolt in the slotted hole on the flexplate.

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1. 16.
   
   Install the inspection cover and the 2 fasteners.

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NOTE: The circlips are unique in size and shape for each shaft. Make sure to use the specified circlip for the application or vehicle damage may occur.
1. 17.
   Install the correct new circlip on the inboard stub shaft.

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NOTE: If the transmission has been replaced or overhauled, the halfshaft seals do not need to be replaced.
1. 18.
   Install a new halfshaft seal. REFER to, Halfshaft Seal - LH .

NOTE: Remove the seal protector before the halfshaft is installed completely.
1. 19.
   Using part: AA5P-4N206-A.

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NOTE: Insert shaft until circlip is fully seated. When checking if circlip is seated do not pull on CV joint or damage can result.
NOTE: After insertion, pull the halfshaft inner end to make sure the circlip is locked.
1. 20.
   

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1. 21.
   
   Install the PTU. REFER to Transfer Case Power Transfer Unit (PTU) .

1. 22.
   
   Install the front subframe. REFER to Uni-Body, Subframe and Mounting System .

1. 23.
   
   Install the top torque converter housing bolts.
   • Tighten to 48 Nm (35 lb-ft).

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1. 24.
   
   Connect the transmission electrical connector and install the wiring harness fastener on the main control cover stud.

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1. 25.
   
   Connect the 2 wiring harness retainers on the transmission.

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1. 26.
   
   Install the ground strap and nut on the main control cover stud bolt.
   • Tighten to 11 Nm (97 lb-in).

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1. 27.
   
   Install the rear starter stud bolt.
   • Tighten to 27 Nm (20 lb-ft).

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1. 28.
   
   Attach the starter wire terminals and install the 2 nuts.
   • Tighten the B+ terminal nut to 12 Nm (106 lb-in).
   • Tighten the S- terminal nut to 5 Nm (44 lb-in).

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1. 29.
   
   Install the starter motor solenoid cover.

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1. 30.
   
   Attach the wiring harness pin-type retainer and connect the selector lever cable to the selector lever cable bracket.

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1. 31.
   
   Place the selector lever in DRIVE.

1. 32.
   
   Place the manual control lever in DRIVE.

   1. 1.
      
      Rotate the manual control lever clockwise until it stops.

   1. 2.
      
      Rotate the manual control lever counterclockwise one detent.

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1. 33.
   
   Unlock the selector lever cable adjuster by sliding the locking tab over.

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1. 34.
   
   Slide the cable end forward or backward to align it with the manual control lever.

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1. 35.
   
   With the adjuster locking tab released, connect the selector lever cable end to the manual control lever.

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1. 36.
   
   Slide the release tab back to lock the adjuster.

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1. 37.
   
   Install the upper intake manifold. For 3.5L Ti-VCT refer to ENGINE - 3.5L GTDI .

1. 38.
   
   Install the battery tray. REFER to Battery, Mounting and Cables .

1. 39.
   
   Install the ACL assembly. REFER to Intake Air Distribution and Filtering .

1. 40.
   
   Fill with clean Motorcraft ®MERCON ® LV Automatic Transmission Fluid to the correct level. Refer to Transmission Fluid Drain and Refill .

1. 41.
   
   After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.

1. 42.
   
   If a replacement transmission assembly is being installed or a new solenoid body is installed, the solenoid body strategy will need to be updated. Refer to Solenoid Body Strategy Download .