REMOVAL & INSTALLATION
- Disconnect the negative battery cable for safety purposes.
- Raise and support the vehicle safely using jackstands.
- Place a drain pan under the transmission fluid pan. Starting at the rear of the pan and working toward the front, loosen the attaching bolts and allow the fluid to drain. Finally, remove all of the pan attaching bolts except two at the front, to allow the fluid to further drain. With the fluid drained, install two bolts on the rear side of the pan to temporarily hold it in place.
- Remove the front exhaust pipes, as necessary, for transmission removal.
- Remove the torque converter cover from the lower end of the converter housing and the adapter plate bolts from the engine oil pan.
Never rotate the crankshaft counterclockwise (looking at the engine from the front of the car).
- Remove the converter-to-flywheel attaching nuts. Place a wrench on the crankshaft pulley attaching bolt to turn the crankshaft and, therefore, the torque converter to gain access to the nuts.
- If equipped with a torque converter drain plug, place a drain pan under the converter to catch the fluid. With the wrench on the crankshaft pulley attaching bolts, turn the converter to gain access to the converter drain plug and remove the plug. After the fluid has been drained, reinstall the plug.
- Disconnect the driveshaft from the rear axle and slide the shaft rearward from the transmission. Position a seal installation tool in the extension housing to prevent fluid leakage.
If a seal installation tool is not available, slip a plastic bag over the extension housing and secure it using rubber bands. This will help to keep the fluid from leaking and causing a mess during the procedure.
- Remove the Vehicle Speed Sensor (VSS) from the transmission case.
- Carefully detach the shift cable from the transmission control lever at the transmission by removing the adjusting nut.
- Disengage all transmission wiring harness and starter motor connectors and position the wiring harness aside. Remove the starter motor.
- Position a transmission floor jack under the transmission and raise it slightly.
- Remove the engine rear support-to-crossmember bolts.
- Remove the crossmember-to-frame side support retaining bolts, then remove the engine and transmission support mount. Remove the engine and transmission support and engine damper mounting body bracket.
- Lower the transmission jack and allow the transmission to hang.
- Using a floor jack beneath the front of the engine, raise the engine to gain access to the two upper converter housing-to-engine block attaching bolts.
- Detach the automatic transmission fluid cooler lines from the transmission, and plug the lines to prevent contamination.
- Remove the lower transmission-to-engine bolts, then remove the transmission fluid fill tube.
- Secure the transmission to the jack with a chain.
If the transmission is to be removed from the vehicle for an extended period of time, support the back end of the engine with a jackstand and wooden block.
- Remove the two upper transmission-to-engine bolts, then carefully move the transmission and converter assembly away from the engine and, at the same time, lower the jack to clear the underside of the vehicle.
- Remove the converter and mount the transmission in a holding fixture.
- Position the converter on the transmission, making sure the converter drive flats are fully engaged in the pump gear by rotating the converter through what feels like two bumps or "notches".
- With the converter properly installed, place the transmission on the jack. Secure the transmission to the jack with a safety chain.
- Rotate the converter until the studs and drain plug are in alignment with the holes in the flywheel.
- Lubricate the pilot bushing.
- Align the yellow balancing marks on the converter and flexplate on models with the 5.0L engine.
- Move the converter and transmission assembly forward into position, taking care not to damage the flywheel and converter pilot. The torque converter must rest squarely against the flywheel, which indicates that the converter pilot is not binding in the engine crankshaft.
Prior to installing and tightening the engine housing-to-flywheel retaining nut, a check should be made to ensure that the torque converter is properly installed. The torque converter should move freely with respect to the flywheel. If it will not move, or moves only grudgingly, remove the transmission and torque converter and reposition the torque converter so that it is properly installed.
- Install and tighten the bolts between the converter housing and the engine to specifications.
- The remainder of installation is the reverse of the removal procedure.
- Be sure to fill the transmission with 3-4 qts. (2.8-3.8L) of clean, new Mercon® Automatic Transmission Fluid (ATF) prior to starting the engine.
- Allow the engine to reach normal operating temperature, then check the ATF level. Add fluid until the transmission is full.
The transmission range selector lever (gearshift handle) should be held against the rearward Drive (D) stop when the linkage is adjusted.
- Position the transmission gearshift handle in the Drive (D) position. Be sure that the lever is tight against the rearward Drive (D) stop.
- Apply the parking brake, block the rear wheels, then raise the front of the vehicle and safely support it on jackstands.
- Loosen the manual control lever shift cable retaining nut, then move the manual control lever to the Drive (D) position. To do this, rotate the control lever as far as possible in the counterclockwise direction, then turn it clockwise to the 3rd detent position (you will feel each detent as the lever is turned).
- With the gearshift handle held against the rear Drive (D) stop and the manual control lever in the Drive (D) position, tighten the retaining nut to 150-203 inch lbs. (17-23 Nm).
- Lower the vehicle and remove the wheel blocks, then start the engine and check the operation of the transmission in each range.