How To Replace Transmission on Ford Expedition and Lincoln Navigator?

The procedure is similar for both ford and Lincoln car models:-----

Its Details for Automatic  Transmission Removal & Installation

The Ford and Lincoln vehicle has 6R80 TRANSMISSION:---

6r80 Transmission

2WD Models

Specific to:

Ford Expedition 2008-2009

Lincoln Navigator 2008-2009

1. Before servicing the vehicle, refer to the precautions section.
2. Disconnect the battery ground cable
3. Remove the driveshaft.
4. Remove the fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the fluid pan to be easily removed when the bolts are removed.
   
   NOTE

   If transmission disassembly or installation of a new transmission is necessary, the transmission fluid will need to be drained.
5. Remove the transmission fluid pan and allow the fluid to drain.
6. Install the fluid pan and tighten the bolts in a crisscross pattern.
7. If equipped, remove the heat shield.
   
   NOTE

   To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket.
8. Move the locking tab up and disconnect the selector lever cable from the manual lever ball stud.
9. Remove the selector lever bracket bolts and remove the bracket.
10. Remove the flexplate inspection cover bolts and the inspection cover.
11. Remove the rubber torque converter nut access plug.
12. Remove and discard the 4 flexplate-to-torque converter nuts.
13. Remove the transmission cooler tube bracket bolt.
14. Remove the transmission case bolt.
15. Remove the transmission fluid cooler tube bracket nut and position the bracket and tubes aside.
16. Remove the plastic starter motor electrical connector cap.
17. Remove the starter motor electrical connectors.
18. Remove the ground wire from the stud.
19. Remove the starter motor bolts and the starter motor.
20. Remove the RH exhaust heat shield bolt.
21. Remove the LH exhaust heat shield and evaporative emissions canister assembly bolts.
22. Disconnect the RH and LH heated oxygen sensors (HO2S) and the catalyst monitor sensor (CMS) electrical connectors.
23. Remove the fuel line bracket bolt and position the bracket and lines aside.
    
    NOTE

    Make sure that the transmission jack makes contact on the outer ribs of the fluid pan. And that the transmission is securely fastened to the transmission jack.
24. Position a suitable high-lift transmission jack under the transmission.
25. Remove the 2 rear crossmember nuts.
26. Remove the 4 crossmember bolts and nuts.
27. Remove the rear crossmember.
28. Remove the 3 bolts and remove the insulator. 
    
    
    
    Fig. Removing the 2 rear crossmember nuts
    
    
    
    
    Fig. Removing the 4 crossmember bolts and nuts and crossmember
    
    
    
    
    Fig. Removing the 3 insulator bolts and insulator
29. Remove the RH and LH exhaust flange nuts.
30. Remove the 2 dual converter Y-pipe bolts and the dual converter Y-pipe.
31. Disconnect the wire harness from the top of the transmission
32. Disconnect the main transmission electrical harness by twisting the outer shell and pulling back on the connector
    
    NOTE

    The top 2 transmission-to-engine bolts need to be removed prior to removing the rest of the bolts. The top left bolt secures the fuel line bracket to the transmission case.
33. Remove the 6 remaining transmission case bolts.
34. Slide the transmission back far enough to install the torque converter retainer tool 307-346. This holds the torque converter in place.
35. Remove the transmission from the vehicle.
    
    WARNING

    If the transmission is to be overhauled or if installing a new transmission, carry out transmission fluid cooler back flushing and cleaning. Make sure the cooler is not restricted. If you have poor cooler flow replace with a new transmission cooler.
    
    
    
    
    

    

    Fig. Locating the remaining transmission housing bolts

To install:

WARNING

The converter housing is piloted into position by dowels in the rear of the engine block. The torque converter must rest squarely against the flexplate. This indicates that the converter pilot is not binding in the engine crankshaft.

1. Position and secure the transmission on the high-lift transmission jack. Raise and position the transmission into the vehicle.
2. Remove the torque converter retainer tool 307-346.
   
   NOTE

   Make sure the torque converter is fully seated in the transmission before aligning the transmission to the engine.
3. With the transmission in a horizontal position, move it toward the engine. Align the orange balancing marks between the torque converter studs and the flexplate bolt holes.
4. Install the transmission case bolts in their correct locations noted during removal.
   
   NOTE

   The top 2 transmission case bolts need to be installed prior to installing the rest of the bolts. The top left bolt is inserted through the fuel line bracket first, then through the transmission case.
5. Install 6 of the 7 transmission case bolts and tighten to 35 ft. lbs. (48 Nm).
6. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place.
7. Connect the wire harness to the top of the transmission.
8. Position the dual converter Y-pipe in place. Install and tighten the 2 dual converter Y-pipe to 30 ft. lbs. (40 Nm).
9. Install the LH and RH exhaust flange nuts and tighten to 30 ft. lbs. (40 Nm).
10. Install the 3 bolts and the insulator, tighten to 66 ft. lbs. (90 Nm).
11. Position the rear crossmember in place and loosely install the transmission insulator nuts.
12. Install the crossmember.
13. Install the 4 crossmember bolts and nuts and tighten to 66 ft. lbs. (90 Nm).
14. Tighten the transmission insulator nuts to 76 ft. lbs. (103 Nm).
15. Install the fuel line bracket tighten the mounting bolt to 18 ft. lbs. (25 Nm).
16. Connect the RH and LH heated oxygen sensors (HO2S) electrical connectors and the CMS electrical connectors.
17. Install the LH exhaust heat shield and evaporative emissions canister assembly bolts. Tighten the bolts to 11 ft. lbs.(15 Nm).
18. Install the RH exhaust heat shield bolt and tighten to 11 ft. lbs.(15 Nm).
19. Position the starter motor in place, install and tighten the 3 starter motor bolts to 19 ft. lbs. (26 Nm).
20. Install the ground wire on the stud, install and tighten the ground wire nut to 17 ft. lbs. 23 (Nm).
21. Install the starter motor electrical connectors. Tighten main power cable to 9 ft. lbs. (15 Nm).
22. Tighten the smaller solenoid feed wire to 53 inch. (6 Nm).
23. Install the plastic starter motor electrical connector cap.
24. Position the transmission cooler tubes in place, install and tighten the bracket nut to 20 ft. lbs. (27 Nm).
25. Align the bracket and install the remaining transmission case bolt. Tighten to 35 ft. lbs. (48 Nm).
    
    NOTE

    Inspect the case to make sure that the old O-rings are not stuck in the case. Install new O-rings on the ends of the cooler lines prior to installing.
26. Install new O-rings on the transmission fluid cooler tubes.
27. Install the transmission cooler tubes and tighten the bracket bolt to 17 ft. lbs. (23 Nm).
28. Install 4 new flexplate-to-torque converter nuts. Tighten the nuts to 26 ft. lbs. (35 Nm).
29. Install the rubber access plug.
30. Install the flexplate inspection cover and tighten the flexplate inspection cover bolts to 26 ft. lbs. (35 Nm).
31. Install the selector lever bracket and tighten the bolts to 35 ft. lbs. (48 Nm).
    
    NOTE

    When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed.
32. With the manual lever in NEUTRAL, connect the selector lever cable onto the manual lever ball stud and move the locking tab down. Listen for the audible click.
33. Pull back on the selector lever cable to make sure that it is correctly installed.
34. If equipped, install the heat shield.
35. Install the driveshaft.
36. Connect the battery ground cable.
37. Verify that the selector lever cable is correctly adjusted.
38. Reflash the transmission control module (TCM) to the latest level of software.
39. Fill the transmission with clean automatic transmission fluid.
40. Test drive and check for leaks.

4WD Models

Specific to:

Ford Expedition 2008-2009

Lincoln Navigator 2008-2009

1. Before servicing the vehicle, refer to the precautions section.
2. Disconnect the battery ground cable.
3. With the vehicle in NEUTRAL, position it on a hoist.
4. Remove the fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the fluid pan to be easily removed when the bolts are removed.
   
   NOTE

   If transmission disassembly or installation of a new transmission is necessary, the transmission fluid will need to be drained.
5. Remove the transmission fluid pan and allow the fluid to drain
6. Install the fluid pan and tighten the bolts in a crisscross pattern.
7. Remove the transfer case.
8. Remove the fuel line bracket bolt and position the bracket and lines aside.
9. If equipped, remove the heat shield.
10. Move the locking tab up and disconnect the selector lever cable from the manual lever ball stud.
11. Remove the selector lever bracket bolts and remove the bracket.
12. Remove the flexplate inspection cover bolts and the inspection cover.
13. Remove the rubber torque converter nut access plug.
14. Remove and discard the 4 flexplate-to-torque converter nuts.
15. Remove the transmission cooler tube bracket bolt.
16. Remove the transmission case bolt.
17. Remove the transmission fluid cooler tube bracket nut and position the bracket and tubes.
18. Remove the plastic starter motor electrical connector cap.
19. Remove the starter motor electrical connectors.
20. Remove the ground wire from the stud.
21. Remove the 3 starter motor bolts and the starter motor.
22. Disconnect the wiring harness from the top of the transmission.
23. Disconnect the main transmission electrical harness by twisting the outer shell and pulling back on the connector.
    
    NOTE

    The top 2 transmission-to-engine bolts need to be removed prior to removing the rest of the bolts. The top left bolt secures the fuel line bracket to the transmission case.
24. Remove the 6 remaining transmission case bolts.
25. Leaving the transmission in a horizontal position, slide it back far enough to install the torque converter holding tool 307-346.
26. Make sure that the torque converter holding tool 307-346 is in place and the transmission is securely fastened to the transmission jack before tilting the transmission.
27. Remove the transmission from the vehicle.
    
    
    

    

    Fig. Locating the remaining transmission housing bolts

To install:

WARNING

The converter housing is piloted into position by dowels in the rear of the engine block. The torque converter must rest squarely against the flexplate. This indicates that the converter pilot is not binding in the engine crankshaft.

1. Position and secure the transmission on the high-lift transmission jack. Raise and position the transmission into the vehicle.
2. Remove the torque converter retainer tool 307-346.
   
   NOTE

   Make sure the torque converter is fully seated in the transmission before aligning the transmission to the engine.
3. With the transmission in a horizontal position, move it toward the engine. Align the orange balancing marks between the torque converter studs and the flexplate bolt holes.
4. Install the transmission case bolts in their correct locations noted during removal.
   
   NOTE

   The top 2 transmission case bolts need to be installed prior to installing the rest of the bolts. The top left bolt is inserted through the fuel line bracket first, then through the transmission case.
5. Install 6 of the 7 transmission case bolts and tighten to 35 ft. lbs. (48 Nm).
6. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place
7. Connect the wire harness to the top of the transmission.
8. Position the starter motor in place, install and tighten the 3 starter motor bolts to 19 ft. lbs. (26 Nm).
9. Install the ground wire on the stud, install and tighten the ground wire nut to 17 ft. lbs. 23 (Nm).
10. Install the starter motor electrical connectors. Tighten main power cable to 9 ft. lbs. (15 Nm).
11. Tighten the smaller solenoid feed wire to 53 inch. (6 Nm).
12. Install the plastic starter motor electrical connector cap.
13. Position the transmission cooler tubes in place, install and tighten the bracket nut to 20 ft. lbs. (27 Nm).
14. Align the bracket and install the remaining transmission case bolt. Tighten to 35 ft. lbs. (48 Nm).
    
    NOTE

    Inspect the case to make sure that the old O-rings are not stuck in the case. Install new O-rings on the ends of the cooler lines prior to installing.
15. Install new O-rings on the transmission fluid cooler tubes.
16. Install the transmission cooler tubes and tighten the bracket bolt to 17 ft. lbs. (23 Nm).
17. Install 4 new flexplate-to-torque converter nuts. Tighten the nuts to 26 ft. lbs. (35 Nm).
18. Install the rubber access plug.
19. Install the flexplate inspection cover and tighten the inspection cover bolts to 26 ft. lbs. (35 Nm).
20. Install the selector lever bracket and tighten the bolts to 35 ft. lbs. (48 Nm).
    
    NOTE

    When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed.
21. With the manual lever in NEUTRAL, connect the selector lever cable onto the manual lever ball stud and move the locking tab down. Listen for the audible click.
22. Pull back on the selector lever cable to make sure that it is correctly installed.
23. If equipped, install the heat shield.
24. Install the fuel line bracket and tighten the mounting bolt to 18 ft. lbs. (25 Nm).
25. Install the transfer case.
26. Connect the battery ground cable.
27. Verify that the selector lever cable is correctly adjusted.
28. Reflash the transmission control module (TCM) to the latest level of software.
29. Fill the transmission with clean automatic transmission fluid.
30. Test drive and check for leaks.

These details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html