Section 07-03B: Transmission, Manual, Model S5-47 ZF
1996 F-Series Vehicles Over 8500 lbs. GVW Workshop Manual
INSTALLATION

Transmission (4x4)

  1. Place the transmission (7003) on a transmission jack such as Rotunda Low Lift Transmission Jack 164-R3900 or equivalent, and install two guide studs in the transmission front case top holes, to guide the transmission into position. Join together the transmission and engine block mating surfaces.

  1. Install the two lower bolts and tighten to 54-68 Nm (40-50 lb-ft). Remove the guide studs and install the upper bolts.

  1. Place the rear support bracket in position and install the retaining bolts. Refer to Section 02-01. Tighten the bolts to 60-80 Nm (45-60 lb-ft).

  1. Install the two bolts at the rear support insulator bracket. Remove the transmission jack.

  1. Position the transfer case (7A195) on the transmission jack. Position the transfer case on the transmission, using care to guide the transfer case shift lever through the opening in the floor pan. Install the gasket and six retaining bolts. Tighten the bolts to specifications listed in the appropriate transfer case section in Group 07 in this manual.

  1. Install the front driveshaft (4602).

  1. Install the rear driveshaft.

  1. NOTE: For vehicles equipped with 7.3L diesel engine, use Synthetic MERCON® Multi-Purpose Automatic Transmission Fluid E6AZ-19582-B or equivalent meeting Ford specification ESR-M2C163-A2.

    Fill transfer case and transmission with Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or -DDX or MERCON® or equivalent.

  1. Connect the backup lamp switch (15520).

  1. Install engine charge exhaust pipe and extension pipe.

  1. Install nuts retaining extension pipe to muffler and pipe assembly. Tighten nuts to 23-33 Nm (17-24 lb-ft).

  1. Remove safety stands and lower vehicle.

  1. Place a new, dry gasket on the upper surface of the shift lever housing. Place the shift lever with the attached guide pieces into the guide piece grooves. The slotted ends of these guide pieces must face upward.

  1.  CAUTION: Do not use any sealant on gasket.

    Tighten the four Allen-head capscrews that secure the cover assembly to the gearshift housing to approximately 10 Nm (7 lb-ft).





  1. Install the upper shift lever to the lower shift lever and tighten the two retaining screws to 22-33 Nm (16-24 lb-ft).

  1. Install the inner boot and the boot and bezel assembly to the transmission opening cover.

  1. Install the shift ball on the upper shift lever if removed.