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Home >> Lincoln >> 2005 >> Aviator AWD >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle/Transmission >> Removal >> Transmission - 4x4

Transmission - 4x4

SPECIAL TOOL(S) CHART

Tool Number Illustration Description
ST1636-A
G03863372Courtesy of FORD MOTOR CO.
 Retainer, Torque Converter 307-346 (T97T-7902-A)
    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.
  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the fan shroud bolts. Do not remove the fan shroud.
  3. Raise and support the vehicle. For additional information, refer to JACKING & LIFTING .
  4. If transmission disassembly or installation of new transmission is necessary, drain the transmission fluid.
    • Install the drain plug when finished.
  5. Remove the 2 RH heat shield bolts and position the RH heat shield aside.
    Fig 1: Positioning RH Heat Shield Aside
    G03863373Courtesy of FORD MOTOR CO.
  6. Disconnect the 2 heated oxygen sensor electrical connectors.
    Fig 2: Disconnecting 2 Heated Oxygen Sensor Electrical Connectors
    G03863374Courtesy of FORD MOTOR CO.
  7. Disconnect the 2 catalyst monitor sensor electrical connectors.
    Fig 3: Disconnecting Catalyst Monitor Sensor Electrical Connectors
    G03863375Courtesy of FORD MOTOR CO.
  8. Remove the RH heat shield bolts.
    Fig 4: Removing RH Heat Shield Bolts
    G03863376Courtesy of FORD MOTOR CO.
  9. Remove the RH heat shield bolt and remove the heat shield.
    Fig 5: Removing RH Heat Shield Bolt
    G03863377Courtesy of FORD MOTOR CO.
  10. Remove the LH heat shield bolt.
    Fig 6: Removing LH Heat Shield Bolt
    G03863378Courtesy of FORD MOTOR CO.
  11. Remove the plastic shield on the right side of the crossmember near the fuel tank.
    Fig 7: Removing Plastic Shield On Right Side Of Crossmember
    G03863379Courtesy of FORD MOTOR CO.
    12. NOTE: RH side shown, LH side similar.
    Fig 8: Removing Upper Crossmember Bolts
    G03863380Courtesy of FORD MOTOR CO.
  12. Remove the 4 upper crossmember bolts (2 on each side).
  13. Remove the bolts, springs, flag nuts and separate the muffler from the converter.
    • Discard the gasket.
    • Discard the flag nuts.
    Fig 9: Remove Bolts, Springs & Flag Nuts
    G03863381Courtesy of FORD MOTOR CO.
    14. NOTE: LH side shown, RH similar.
    Fig 10: Removing Converter-To-Manifold Nuts
    G03863382Courtesy of FORD MOTOR CO.
  14. Remove the 4 converter-to-manifold nuts.
  15. Install a suitable jackstand under the transfer case.
    Fig 11: Installing Suitable Jackstand Under Transfer Case
    G03863383Courtesy of FORD MOTOR CO.
  16. Remove the RH side crossmember bolts.
    Fig 12: Removing RH Side Crossmember Bolts
    G03863384Courtesy of FORD MOTOR CO.
  17. Remove the LH side crossmember bolts.
    Fig 13: Removing LH Side Crossmember Bolts
    G03863385Courtesy of FORD MOTOR CO.
  18. Remove the transmission support insulator nuts and remove the crossmember.
    Fig 14: Removing Transmission Support Insulator Nuts
    G03863386Courtesy of FORD MOTOR CO.
    19. NOTE: This step may require an assistant.
    Fig 15: Removing Bolts
    G03863387Courtesy of FORD MOTOR CO.
  19. Remove the transmission mounted exhaust hanger and the 3-way converter system.
    1. Remove the bolt and converter assembly.
    2. If required, remove the 2nd bolt and mount.
  20. Remove the shift cable and bracket.
    Fig 16: Removing Shift Cable And Bracket
    G03863388Courtesy of FORD MOTOR CO.
  21. Position the manual lever out of park.
    Fig 17: Positioning Manual Lever Out Of Park
    G03863389Courtesy of FORD MOTOR CO.
  22. Index-mark the front axle pinion flange and the front driveshaft.
    Fig 18: Indexing-Mark Front Axle Pinion Flange And Front Driveshaft
    G03863390Courtesy of FORD MOTOR CO.
  23. Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.
    Fig 19: Index-Marking Front Output Shaft Assembly
    G03863391Courtesy of FORD MOTOR CO.
  24. Remove and discard the bolts and washers.
    Fig 20: Removing Bolts And Washers
    G03863392Courtesy of FORD MOTOR CO.
  25. Remove and discard the bolts and universal joint retainers.
    Fig 21: Removing Bolts And Universal Joint Retainers
    G03863393Courtesy of FORD MOTOR CO.
    26. CAUTION: 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.
    CAUTION: 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.
    Fig 22: Removing Driveshaft
    G03863394Courtesy of FORD MOTOR CO.
  26. Remove the driveshaft.
    27. NOTE: Pinion flange shown, transfer case flange similar.
    Fig 23: Removing Rear Driveshaft Bolts
    G03863395Courtesy of FORD MOTOR CO.
  27. Remove the rear driveshaft bolts.
    1. Mark the location of the flanges.
    2. Remove the 4 bolts.
    28. NOTE: Do not use a hammer.
    Fig 24: Removing Driveshaft From Flange
    G03863396Courtesy of FORD MOTOR CO.
  28. Remove the driveshaft from the flange using a pry bar.
  29. Remove the electrical connector cover.
    Fig 25: Removing Electrical Connector Cover
    G03863397Courtesy of FORD MOTOR CO.
  30. Remove the starter wire and the positive battery cable.
    Fig 26: Removing Starter Wire
    G03863398Courtesy of FORD MOTOR CO.
  31. Remove the starter motor bolts and starter.
    Fig 27: Removing Starter Motor Bolts
    G03863399Courtesy of FORD MOTOR CO.
  32. Remove the flexplate cover.
    Fig 28: Removing Flexplate Cover
    G03863400Courtesy of FORD MOTOR CO.
  33. Remove the access cover.
    Fig 29: Removing Access Cover
    G03863401Courtesy of FORD MOTOR CO.
    34. NOTE: Make an identifying mark on the nut, stud and flexplate to allow for correct installation.
    Fig 30: Removing Torque Converter Nuts
    G03863402Courtesy of FORD MOTOR CO.
  34. Remove the 4 torque converter nuts.
  35. Lower the transmission to gain access to the sensor connectors and the transmission bolts.
  36. Disconnect the RH catalyst monitor connector and the fuel lines from the bracket.
    Fig 31: Disconnecting RH Catalyst Monitor Connector
    G03863403Courtesy of FORD MOTOR CO.
  37. Disconnect the RH heated oxygen sensor from the transmission.
    Fig 32: Disconnecting RH Heated Oxygen Sensor From Transmission
    G03863404Courtesy of FORD MOTOR CO.
  38. If equipped, disconnect the shift motor electrical connector.
    Fig 33: Disconnecting Shift Motor Electrical Connector
    G03863405Courtesy of FORD MOTOR CO.
  39. Disconnect the LH heated oxygen sensor and the harness clip from the transmission.
    Fig 34: Disconnecting LH Heated Oxygen Sensor And Harness Clip
    G03863406Courtesy of FORD MOTOR CO.
  40. Disconnect the LH catalyst monitor connector from the transmission.
    Fig 35: Disconnecting LH Catalyst Monitor Connector From Transmission
    G03863407Courtesy of FORD MOTOR CO.
  41. Move the rubber boot back to gain access to the connector.
    Fig 36: Moving Rubber Boot Back To Gain Access To Connector
    G03863408Courtesy of FORD MOTOR CO.
  42. Disconnect the digital transmission range (TR) sensor connector.
    Fig 37: Disconnecting Digital Transmission Range (TR) Sensor Connector
    G03863409Courtesy of FORD MOTOR CO.
  43. Disconnect the turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor and intermediate shaft speed (ISS) sensor electrical connectors.
    Fig 38: Disconnecting Turbine Shaft Speed (TSS) Sensor
    G03863410Courtesy of FORD MOTOR CO.
    44. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector.
    Fig 39: Removing Screw From Solenoid Body Connector
    G03863411Courtesy of FORD MOTOR CO.
  44. Remove the screw from the solenoid body connector and disconnect the connector.
  45. Disconnect the harness retainers.
    Fig 40: Disconnecting Harness Retainers
    G03863412Courtesy of FORD MOTOR CO.
    46. CAUTION: Do not damage the cooler tubes. Hold the transmission case fittings with a wrench.
    Fig 41: Disconnecting Transmission Cooler Tubes
    G03863413Courtesy of FORD MOTOR CO.
  46. Disconnect the transmission cooler tubes.
    47. WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.
  47. Support the transmission with a transmission jack.
  48. Remove the jackstand from under the transfer case.
    Fig 42: Removing Jackstand From Under Transfer Case
    G03863414Courtesy of FORD MOTOR CO.
    49. NOTE: RH side shown, LH side similar.
    Fig 43: Removing Front Crossmember Bolts
    G03863415Courtesy of FORD MOTOR CO.
  49. Remove the 4 front crossmember bolts and the crossmember.
  50. Remove the 7 engine-to-transmission retaining bolts.
    Fig 44: Removing 7 Engine-To-Transmission Retaining Bolts
    G03863416Courtesy of FORD MOTOR CO.
  51. Lower the transmission and transfer case as an assembly from the vehicle.
  52. Install the special tool.
    Fig 45: Installing Special Tool
    G03863417Courtesy of FORD MOTOR CO.
    53. NOTE: If the transmission is being serviced, the transfer case will need to be removed.
    Fig 46: Removing Transfer Case From Transmission
    G03863418Courtesy of FORD MOTOR CO.
  53. Remove the transfer case from the back of the transmission.
    • Remove the bolts and the bracket.
    • Disconnect the vent hose.
  54. Carry out the transmission fluid cooler backflushing and cleaning if the transmission is being overhauled or installing a new or remanufactured transmission. For additional information, refer to TRANSMISSION FLUID COOLER - BACKFLUSHING AND CLEANING .
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