Ford F150 Pickup. Manual — part 1826

transmission-to-engine bolts. Install the upper transmission fluid fill tube. Install the transmission fluid
fill tube bolt on the right side of the cylinder head. On all engines, connect the transmission fluid cooler
tubes.

3. Position the exhaust hanger, the rear transmission insulator and install the bolts. On 4.2L and 4.6L

engines, install the nut for the exhaust bracket. See Fig. 6 . On 5.4L engines, install the exhaust bracket
nut. See Fig. 7 . On all engines, position the crossmember and loosely install the mount-to-crossmember
nuts. Install the 6 crossmember-to-frame nuts and bolts (3 on each side). See Fig. 5 .

4. Lower the transmission on the crossmember and tighten the rear mount nuts. Remove the high-lift

transmission jack. Install the two bolts retaining the heat shield to the transmission support crossmember.
See Fig. 4 . Connect the solenoid body assembly electrical connector. Install the wire harness bracket and
install the nuts. See Fig. 3 . Connect the digital Transmission Range (TR) sensor. Connect the Output
Shaft Speed (OSS) sensor.

5. Install the shift cable bracket and connect the transmission shift linkage. On V8 engines, Install the torque

converter nuts. Install the rubber access plug. See Fig. 2 . Install the transmission inspection cover. On
V6 engine, install torque converter nuts. Install the rubber access plug. See Fig. 1 . Install starter motor
bolt and stud bolt. On V8 engines, to install the starter motor, position the starter. Install the two bolts.
Install the stud bolt. On all engines, connect the starter motor electrical connectors. Install the starter
motor solenoid terminal cover.

6. On 4x4 vehicles, install the transfer case. See OVERHAUL article in TRANSFER CASES. Align the

marks made during removal, install the front driveshaft flange and the four bolts. On 4x2 vehicles, install
the rear driveshaft.

7. On all vehicles, use the following guidelines for the in-line transmission fluid filter:

z

If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install
a new in-line fluid filter.

z

If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter,
install a new in-line fluid filter kit.

z

If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter
kit.

z

If installing a Ford-authorized remanufactured transmission, install the in-line transmission fluid
filter that is supplied.

Prior to lowering the vehicle, install a new in-line transmission filter or a filter kit.

8. Connect the battery ground cable. Fill the transmission to the correct level with clean automatic

transmission fluid. Check the transmission for correct operation.

4R100

Removal

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 may
experience slightly different upshifts (either soft or firm) and that this is
temporary and will eventually return to normal operating condition.

2003 Ford Pickup F150

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - F150 Pickup

1. Position the vehicle on a hoist. Place in Neutral. Disconnect the battery ground cable.

2. On 4x4 vehicles, remove the transfer case. See OVERHAUL article in TRANSFER CASES. To maintain

initial driveshaft balance, mark the front driveshaft yoke and flange so they can be installed in their
original location. Remove the four front driveshaft flange bolts. Remove the front driveshaft. On 4x2
vehicles, remove the rear driveshaft.

3. On all vehicles, if disassembly of the transmission or installation of a new transmission is required, drain

the transmission fluid. On vehicles equipped with a fluid pan drain plug, remove the fluid pan drain plug
and allow the fluid to drain. Install the fluid drain plug.

4. On vehicles not equipped with a fluid pan drain plug, remove the transmission fluid pan and gasket.

Loosen, but do not remove the bolts. Remove the front and side bolts. Lower the front of the fluid pan
and allow the fluid to drain. Remove the remaining fluid pan bolts and the fluid pan. Do not discard the
gasket unless damaged. This is a reusable gasket.

5. Apply a light coat of petroleum jelly to hold the gasket in place in the fluid pan. Position the gasket onto

the clean fluid pan. Make sure the magnet is positioned over the dimple in the fluid pan. Install the pan
with the gasket. Alternately tighten the bolts.

6. On all vehicles, remove the plastic cover from the starter motor electrical connector. Disconnect the

starter motor electrical connectors. Remove the stud bolt. Remove the two bolts. Remove the starter.

7. Remove the flexplate inspection cover bolts and remove the flexplate inspection cover. Remove the

torque converter access cover. See Fig. 10 . Remove and discard the four torque converter nuts.

8. On 4x4 vehicles, using a suitable transmission jack, support the transmission. Position a suitable

transmission jack and secure the transmission to it with a safety strap. Remove the jack stand.

9. On 4x2 vehicles, using a suitable transmission jack, support the transmission and secure the transmission

to it with a safety strap. Remove the 2 exhaust heat shield-to-crossmember bolts (one on each side). See
Fig. 11 . Loosen, but do not remove the transmission mount-to-crossmember nuts. Remove the 6
crossmember-to-frame nuts and bolts (3 on each side). See Fig. 5 . Remove the transmission mount-to-
crossmember nuts, and remove the crossmember. Remove the transmission mount and the exhaust
hanger.

10. On all vehicles, disconnect the shift cable from the transmission. Disconnect the shift cable from the

manual control lever. Disconnect the cable housing from the bracket and position aside. Disconnect the
Digital Transmission (TR) sensor connector. Disconnect the Turbine Shaft Speed (TSS) sensor and the

NOTE:

Do not discard the fluid pan gasket unless damaged. This is a reusable
gasket.

CAUTION: Make sure any securing straps do not touch the Cooler Bypass Valve

(CBV). Do not use the CBV as a handle. Damage to the CBV can
cause a leak and/or a failure to the transmission assembly.

CAUTION: Make sure any securing straps do not touch the Cooler Bypass Valve

(CBV). Do not use the CBV as a handle. Damage to the CBV can
cause a leak and/or a failure to the transmission assembly.

2003 Ford Pickup F150

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - F150 Pickup

Output Shaft Speed (OSS) sensor.

11. Remove the nut and disconnect the fuel line bracket. See Fig. 12 . Disconnect the transmission fluid

cooler tubes from the Cooler Bypass Valve (CBV). Disconnect the solenoid body connector. Disconnect
the HEGO sensor connector. Disconnect the two harness routing clips.

12. Lower the transmission to gain access to the retaining bolts. Remove the 7 bolts. Gently rock the

transmission side-to-side to disengage it from the locator dowels. Move the transmission and the
transmission jack rearward to clear the flexplate, and partially lower the transmission. Disconnect the
wire harness routing clip at the top of the transmission.

13. Using the special tool, secure the torque converter to the transmission. See Fig. 8 . The front of the

transmission will need to be lowered in order for the transmission to clear the exhaust system during
removal. See Fig. 9 . Tilt the front of the transmission down and lower the transmission from the vehicle.

14. Continue moving the transmission rearward, while gradually lowering the front of the transmission. As

the transmission jack is being lowered, move the transmission forward and remove it from the vehicle.

15. Carry out the transmission fluid cooler-backflushing and cleaning procedure if a new transmission is

being installed or overhauled. See TRANSMISSION FLUID COOLER BACK FLUSHING &
CLEANING .

WARNING:

The torque converter is heavy and can result in injury if it falls out of
the transmission.

CAUTION: Do not use the CBV as a handle, damage to the CBV assembly or the

transmission case can occur.

NOTE:

If the torque converter falls out of the transmission and is dropped, the
installation of a new torque converter will be necessary.

2003 Ford Pickup F150

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - F150 Pickup

Fig. 10: Locating Torque Converter Access Cover
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - F150 Pickup