How to remove Transmission on 2005 Ford Explorer?

Transmission Removal & Installation 

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the transmission fluid.
3. Place the transmission in Neutral .
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Fluid level indicator

   Fan shroud

   Transfer case on 4WD vehicles

   Rear driveshaft after matchmarking the yoke and axle flange

   Starter

   Access cover and adapter plate bolts from the lower left side of the converter housing, on all other applications

   Flywheel-to-converter attaching nuts. Use a socket and breaker bar on the crankshaft pulley attaching bolt. Rotate the pulley clockwise as viewed from the front to gain access to each of the nuts.

   Shifter cable

   Transmission wire harness

   Heated Oxygen (HO ₂ S) sensor connector

   Transmission connector

   Digital Transmission Range (TR) sensor connector

   Catalytic converter

   Speedometer cable and/or vehicle speed sensor from the transfer case (4WD) or extension housing (2WD)

   Transmission cooler lines

   Engine rear support-to-crossmember bolts and the crossmember-to-frame side support attaching nuts and bolts

   Crossmember

   Transmission mount

   Transmission upper fill tube

   Vent tube on 4WD vehicles

   Converter housing-to-engine bolts
5. Move the transmission to the rear so it disengages from the dowel pins and the converter is disengaged from the flywheel. Lower the transmission from the vehicle.
6. Remove the torque converter from the transmission, if necessary.

To install:

1. Install the converter on the transmission.
   
   WARNING

   Before installing an automatic transmission, always check that the torque converter is fully seated into the transmission. Typically, the converter has notches or tangs on the hub that must engage the transmission fluid pump. If they are not engaged in the pump, the transmission will not mate to the engine properly, as the converter will be holding it away. Severe damage to the pump, converter or transmission casting can occur if the transmission-to-engine bolts are tightened to force the transmission to mate to the engine.

Proper installation of the converter requires full engagement of the converter hub in the pump gear. To accomplish this, the converter must be pushed and at the same time rotated through what feels like 2 notches or bumps. When fully installed, rotation of the converter will usually result in a clicking noise heard, caused by the converter surface touching the housing to case bolts.

For reference, a properly installed converter will have a distance from the converter pilot nose from face-to-converter housing outer face of ¹³ / ₃₂ - ⁹ / ₁₆ in. (10.5-14.5mm).

1. Rotate the converter so that the drive studs are in alignment with the holes in the flywheel.
2. Move the converter and transmission assembly forward into position, being careful not to damage the flywheel and converter pilot. The converter housing is piloted into position by the dowels in the rear of the engine block.
   
   NOTE

   During this move, to avoid damage, do not allow the transmission to get into a nose down position as this will cause the converter to move forward and disengage from the pump gear.
3. Install or connect the following:
   
   
   Converter housing to engine. Torque the bolts to 30-41 ft. lbs. (40-55 Nm). The 2 longer bolts are located at the dowel holes.

   Upper fluid filler tube and bracket. Torque the bolt to 41 ft. lbs. (55 Nm).

   Transfer case, 4WD vehicles

   Exhaust bracket. Torque the bolts to 64 ft. lbs. (87 Nm).

   Crossmember. Torque the bolts to 87 ft. lbs. (118 Nm).

   Transmission mount. Torque the bolts to 81 ft. lbs. (110 Nm).

   Transmission cooler lines. Torque the bolts to 23 ft. lbs. (31 Nm).

   Starter. Torque the bolts to 30 ft. lbs. (40 Nm).

   Transmission wire harness

   HO ₂ S sensor

   Transmission connector

   TR sensor connector

   Shift cable and bracket

   Driveshaft. Torque the bolts to 95 ft. lbs. (129 Nm).

   Shroud. Torque the bolts to 71 inch lbs. (8 Nm).

   Fluid level indicator

   Negative battery cable
4. Fill the transmission to the proper level.
5. Start the vehicle and check for leaks, repair if necessary.

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Place the transmission in Neutral .
3. Remove or disconnect the following:
   
   
   Negative battery cable

   Transfer case

   Three-way catalytic converter
4. If transmission disassembly is necessary, drain the transmission fluid.
5. Support the transmission with a transmission jack.
6. Remove or disconnect the following:
   
   NOTE

   Clean the area around connector to prevent contamination of the solenoid body connector.
   
   
   
   
   Right heat shield

   Left heat shield bolt

   Plastic cover from the right side of the frame rail

   Plastic shield on the right side of the crossmember near the fuel tank

   The two upper crossmember bolts (two on each side)

   Right side lower crossmember bolts

   Left side lower crossmember bolts

   Transmission support insulator nuts and remove the crossmember

   The two bolts and remove the transmission support insulator

   Shift cable and bracket

   Turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor and intermediate shaft speed (ISS) sensor electrical connectors
7. Remove or disconnect the following:
   
   WARNING

   Do not damage the cooler tubes
   
   
   
   NOTE

   Make an identifying mark on the nut, stud, and adapter plate to allow for correct installation.
   
   
   
   
   Screw from the solenoid body connector and disconnect the connector

   Harness retainers

   Left side heated oxygen sensor (HO2S) connector from the bracket

   Digital transmission range (TR) sensor connector

   Starter
   
   
   
   
   Transmission cooler tubes

   Access cover
   
   
   
   
   The 4 torque converter nuts

   The 7 engine-to-transmission retaining bolts
8. Lower the transmission from the vehicle.

To install:

1. Raise and position the transmission.
2. Align the flexplate to converter marks made at removal.
3. Install seven engine to transmission retaining bolts. Torque to 35 ft. lbs. (48 Nm).
4. Install the four torque converter nuts. Torque to 28 ft. lbs. (48 Nm).
5. Install or connect the following:
   
   WARNING

   Damage will occur to the solenoid body assembly if the screw is tightened above 44 inch lbs. (5 Nm). Always install new O-ring seals on vehicle harness connector. Clean the area around connector to prevent contamination of the solenoid body connector. Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
   
   
   
   
   Access cover

   Transmission cooler tubes

   Starter

   Digital transmission range (TR) sensor connector

   Left side heated oxygen sensor (HO2S) to the bracket

   Wire harness, and install the retainers
6. Install and lubricate new O-ring seals on the transmission connector and connect the connector.
7. Install or connect the following:
   
   NOTE

   Ford recommends, if the vehicle was not equipped with a fluid filter, install a Fluid Filter Service Kit (XC3Z-7B155-AA). Follow the instructions supplied in the kit. If the vehicle was equipped with a fluid filter, install a new filter (XC3Z-7B155-AB).
   
   
   
   
   Turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor, and intermediate shaft speed (ISS) sensor electrical connectors.

   Shift cable and bracket

   Three-way catalytic converter

   Transmission support insulator. Torque to 68 ft. lbs. (90 Nm).

   Crossmember in place and loosely install the two nuts to hold up the crossmember.

   Crossmember bolts. Torque to 52 ft. lbs. (70 Nm).

   Rear transmission support nuts. Torque to 52 ft. lbs. (70 Nm).

   Heat shields

   Plastic cover to the right side of the frame rail

   Plastic shield on the right side of the crossmember near the fuel tank

   Transfer case
8. Connect the battery ground cable.
9. Verify that the shift cable is correctly adjusted.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Place the transmission in Neutral .
3. Remove or disconnect the following:
   
   
   Negative battery cable

   Transfer case

   Three-way catalytic converter
4. If transmission disassembly is necessary, drain the transmission fluid.
5. Support the transmission with a transmission jack.
6. Remove or disconnect the following:
   
   NOTE

   Clean the area around connector to prevent contamination of the solenoid body connector.
   
   
   
   
   RH heat shield

   LH heat shield bolt

   Plastic cover from the right side of the frame rail

   Plastic shield on the right side of the crossmember near the fuel tank

   The two upper crossmember bolts (two on each side)

   RH side lower crossmember bolts

   LH side lower crossmember bolts

   Transmission support insulator nuts and remove the crossmember

   The two bolts and remove the transmission support insulator

   Shift cable and bracket

   Turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor and intermediate shaft speed (ISS) sensor electrical connectors
7. Remove or disconnect the following:
   
   WARNING

   Do not damage the cooler tubes
   
   
   
   NOTE

   Make an identifying mark on the nut, stud, and adapter plate to allow for correct installation.
   
   
   
   
   Screw from the solenoid body connector and disconnect the connector

   Harness retainers

   Left side heated oxygen sensor (HO2S) connector from the bracket

   Digital transmission range (TR) sensor connector

   Starter
   
   
   
   
   Transmission cooler tubes

   Access cover
   
   
   
   
   The 4 torque converter nuts

   The 7 engine-to-transmission retaining bolts
8. Lower the transmission from the vehicle.

To install:

1. Raise and position the transmission.
2. Align the flexplate to converter marks made at removal.
3. Install seven engine to transmission retaining bolts. Torque to 35 ft. lbs. (48Nm).
4. Install the four torque converter nuts. Torque to 28 ft. lbs. (48Nm).
5. Install or connect the following:
   
   WARNING

   Damage will occur to the solenoid body assembly if the screw is tightened above 44 inch lbs. (5Nm). Always install new O-ring seals on vehicle harness connector. Clean the area around connector to prevent contamination of the solenoid body connector. Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
   
   
   
   
   Access cover

   Transmission cooler tubes

   Starter

   Digital transmission range (TR) sensor connector

   Left side heated oxygen sensor (HO2S) to the bracket

   Wire harness, and install the retainers
6. Install and lubricate new O-ring seals on the transmission connector and connect the connector.
7. Install or connect the following:
   
   NOTE

   If the vehicle was not equipped with a fluid filter, install a Fluid Filter Service Kit (XC3Z-7B155-AA). Follow the instructions supplied in the kit. If the vehicle was equipped with a fluid filter, install a new filter (XC3Z-7B155-AB).
   
   
   
   
   Turbine shaft speed (TSS) sensor, output shaft speed (OSS) sensor, and intermediate shaft speed (ISS) sensor electrical connectors.

   Shift cable and bracket

   Three-way catalytic converter

   Transmission support insulator. Torque to 68 ft. lbs. (90Nm).

   Crossmember in place and loosely install the two nuts to hold up the crossmember.

   Crossmember bolts. Torque to 52 ft. lbs. (70Nm).

   Rear transmission support nuts. Torque to 52 ft. lbs. (70Nm).

   Heat shields

   Plastic cover to the right side of the frame rail

   Plastic shield on the right side of the crossmember near the fuel tank

   Transfer case
8. Connect the battery ground cable.
9. Verify that the shift cable is correctly adjusted.