Transmission — 3.7L and 5.0L (4V)

 WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

All vehicles

1. NOTE: Before installing the transmission, clean and lubricate the input shaft with a small amount of grease.

   Position the transmission to the engine.

2. Install the 4 transmission-to-engine bolts and 3 transmission-to-engine stud bolts.
   • Tighten to 48 Nm (35 lb-ft).

Vehicles equipped with a 3.7L engine

3. Install the 2 engine-to-transmission bolts.
   • Tighten to 48 Nm (35 lb-ft).

All vehicles

4. Connect the clutch slave cylinder tube to the clutch slave cylinder connector.
   • Attach the clutch hydraulic tube clip.

5. Position the wiring harness and connect the wiring harness clips.
   • If equipped, connect the skip shift solenoid.

6. Partially raise the transmission.

7. Install the transmission crossmember. Refer to Section 502-00 .

8. Install the 2 gearshift lever nuts.
   • Tighten to 11 Nm (97 lb-in).

9. Install the starter motor. Refer to Section 303-06 .

10. Install the subframe cross brace and the 4 subframe cross brace nuts.
    • Tighten to 48 Nm (35 lb-ft).

11. Install the driveshaft. Refer to Section 205-01 .

Vehicles equipped with a 3.7L engine

12. Connect the OSS sensor and the reverse lamp switch electrical connectors.

13. Install the catalytic converter assembly (H-pipe). Refer to Section 309-00 .

Vehicles equipped with a 5.0L (4V) engine

14. Install the 2 engine spacer plate-to-transmission bolts.
    • Tighten to 35 Nm (26 lb-in).

15. NOTE: Prior to installing the catalytic converter (H-pipe) assembly, inspect the HO2S and the CMS wiring harness for damage.

    Using new gaskets, position the catalytic converter (H-pipe) assembly to the vehicle and support with a suitable jackstand.

16. NOTE: Tighten the catalytic converter-to-exhaust manifold nuts alternately in 10 Nm (89 lb-in) increments to maintain torque and to draw the flange evenly making sure correct alignment of the exhaust system.

    Install 2 new LH catalytic converter-to-exhaust manifold nuts.
    • Tighten to 40 Nm (30 lb-ft).

17. NOTE: Tighten the catalytic converter-to-exhaust manifold nuts alternately in 10 Nm (89 lb-in) increments to maintain torque and to draw the flange evenly making sure correct alignment of the exhaust system.

    Install 2 new RH catalytic converter-to-exhaust manifold nuts.
    • Tighten to 40 Nm (30 lb-ft).

18. Tighten the 2 exhaust (H-pipe) clamps.
    • Tighten to 48 Nm (35 lb-ft).

19. NOTE: Inspect the CMS and reverse lamp switch wiring harness for damage.

    Connect the CMS and the reverse lamp switch electrical connectors.

20. NOTE: Inspect the CMS and OSS wiring harness for damage.

    Connect the CMS and the OSS sensor electrical connectors.

All vehicles

21. NOTICE: The use of any other transmission fluid than specified can result in the transmission failing to operate in a normal manner or transmission failure.

    Check, and as necessary, fill the transmission with transmission fluid.

22. Lightly pull up on the gearshift lever boot to fully seat the gearshift lever boot to the floor pan.

23. Install the floor console finish panel and the gearshift lever knob.
    • Engage anti-rotation tabs of trim boot into holes at top of gearshift lever.
    • Turn the gearshift lever knob in a clockwise direction.

24. NOTE: 5.0L (4V) engine shown, 3.7L engine similar.

    Install the engine appearance cover.

25. If equipped, install the strut tower cross brace and 4 nuts.
    • Tighten to 35 Nm (26 lb-ft).

26. Connect the battery ground cable. Refer to Section 414-01 .

27.  WARNING: Carefully read cautionary information on product label. For emergency medical information seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.

    NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

    Fill the brake and clutch reservoir. Bleed the clutch hydraulic system. Refer to Section 308-02 .