Installation

Transmission - Boss(R) 302





WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

1. NOTE: Before installing the transmission, clean and lubricate the input shaft with a small amount of grease.
Position the transmission to the engine.


2. Install the 4 transmission-to-engine bolts and 3 transmission-to-engine stud bolts.
- Tighten to 48 Nm (35 lb-ft).


3. Connect the clutch slave cylinder tube to the clutch slave cylinder connector.
- Attach the clutch hydraulic tube clip.






4. Position the wiring harness and connect the wiring harness clips.
- If equipped, connect the skip shift solenoid.


5. Partially raise the transmission.

6. Using the adjustable jackstands, raise the subframe to the marked position.





7. NOTE: LH shown, RH similar.
Install the 4 rear subframe bolts.

- Tighten to 115 Nm (85 lb-ft).






8. NOTE: LH shown, RH similar.
Tighten the 4 front subframe nuts.

- Tighten to 115 Nm (85 lb-ft).






9. Connect the steering column shaft and install the new steering column shaft pinch bolt.
- Tighten to 48 Nm (35 lb-ft).






10. Install the transmission crossmember.

11. Install the 2 gearshift lever nuts.
- Tighten to 11 Nm (97 lb-in).






12. Install the starter motor.

13. Install the subframe cross brace and the 4 subframe cross brace nuts.
- Tighten to 48 Nm (35 lb-ft).






14. Install the driveshaft.

15. Install the 2 engine spacer plate-to-transmission bolts.
- Tighten to 35 Nm (26 lb-in).






16. Connect the Output Shaft Speed (OSS) sensor and the reverse lamp switch electrical connectors.





17. NOTICE: Do not bend, twist or allow the exhaust side pipes to hang from the flexible bellows or damage to the exhaust side pipe may occur.

Install the RH and LH catalytic converters.

18. Install the crossmember brace and 6 crossmember brace bolts.
- Tighten to 48 Nm (35 lb-ft).






19. Tighten the 2 crossmember brace nuts.
- Tighten to 48 Nm (35 lb-ft).






20. Install the lower air deflector and install the 9 screws.





21. NOTICE: The use of any other transmission fluid than specified can result in the transmission failing to operate in a normal manner or transmission failure.

Check, and as necessary, fill the transmission with transmission fluid.


22. Install the 2 dash boot bearing nuts.
- Tighten to 9 Nm (80 lb-in).






23. Lightly pull up on the gearshift lever boot to fully seat the gearshift lever boot to the floor pan.





24. Install the floor console finish panel and the gearshift lever knob.
- Engage anti-rotation tabs of trim boot into holes at top of gearshift lever.

- Turn the gearshift lever knob in a clockwise direction.






25. Install the strut tower cross brace and 4 nuts.
- Tighten to 35 Nm (26 lb-ft).






26. Connect the battery ground cable.

27. WARNING: Carefully read cautionary information on product label. For emergency medical information seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.

NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

Fill the brake and clutch reservoir. Bleed the clutch hydraulic system.