Ford F150 Pickup. Instruction - 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.  

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

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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 

instruction 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