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From in the engine compartment, remove the two upper converter housing-to-engine bolts.
Disconnect the neutral switch wire at the in-line connector.
Remove the bolt securing the fluid filler tube to the engine cylinder head.
Raise and support the truck on jackstands.
Place the drain pan under the transmission fluid pan. Starting at the rear of the pan and working toward the front, loosen the attaching bolts and allow the fluid to drain. Finally remove all of the pan attaching bolts except two at the front, to allow the fluid to further drain. With fluid drained, install two bolts on the rear side of the pan to temporarily hold it in place.
Remove the converter drain plug access cover from the lower end of the converter housing.
Remove the converter-to-flywheel attaching nuts. Place a wrench on the crankshaft pulley attaching bolt to turn the converter to gain access to the nuts.
With the wrench on the crankshaft pulley attaching bolt, turn the converter to gain access to the converter drain plug. Place a drain pan under the converter to catch the fluid and remove the plug. After the fluid has been drained, reinstall the plug.
On 2WD drive models, disconnect the driveshaft from the rear axle and slide shaft rearward from the transmission. Install a seal installation tool in the extension housing to prevent fluid leakage.
Disconnect the speedometer cable from the extension housing.
Disconnect the downshift and manual linkage rods from the levers at the transmission.
Disconnect the oil cooler lines from the transmission.
Remove the vacuum hose from the vacuum diaphragm unit. Remove the vacuum line retaining clip.
Disconnect the cable from the terminal on the starter motor. Remove the three attaching bolts and remove the starter motor.
On 4WD drive models remove the transfer case.
Remove the two engine rear support and insulator assembly-to-attaching bolts.
Remove the two engine rear support and insulator assembly-to-extension housing attaching bolts.
Remove the six bolts securing the No. 2 crossmember to the frame side rails.
Raise the transmission with a transmission jack and remove both crossmembers.
Secure the transmission to the jack with the safety chain.
Remove the remaining converter housing-to-engine attaching bolts.
Move the transmission away from the engine. Lower the jack and remove the converter and transmission assembly from under the vehicle.
Tighten the converter drain plug.
Position the converter on the transmission making sure the converter drive flats are fully engaged in the pump gear.
With the converter properly installed, place the transmission on the jack. Secure the transmission on the jack with the chain.
Rotate the converter until the studs and drain plug are in alignment with their holes in the flywheel.
Move the converter and transmission assembly forward into position, using care not to damage the flywheel and the converter pilot. The converter must rest squarely against the flywheel. This indicates that the converter pilot is not binding in the engine crankshaft.
Install the converter housing-to-engine attaching bolts and tighten them to 65 ft. lbs. (88 Nm) for the diesel; 50 ft. lbs. (68 Nm) for gasoline engines.
Remove the transmission jack safety chain from around the transmission.
Position the No. 2 crossmember to the frame side rails. Install and tighten the attaching bolts.
Install transfer case on 4WD drive models.
Position the engine rear support and insulator assembly above the crossmember. Install the rear support and insulator assembly-to-extension housing mounting bolts and tighten the bolts to 45 ft. lbs. (61 Nm).
Lower the transmission and remove the jack.
Secure the engine rear support and insulator assembly to the crossmember with the attaching bolts and tighten them to 80 ft. lbs. (108 Nm).
The balance of installation is the reverse of removal.
first remove both front and rear driveshafts. Then remove skid plate underneath transfer case. Remember to unplug the electric motor wiring harness for explorers with electronic four wheel drive switching. Remove vacuum line on the top of transfer case. Unbolt Speedometer cable mount from top/rear of transfer case. Remove five bolts connecting the transfer case to the transmission, this step will cause some transmission fluid to leak from the shaft housing (approx. half a litre) so place a drain pan underneath. Remember to either place a jack or wood blocking under transfer case before removing the last bolt connecting the transfer case as it is heavy (approx. 80-90 lbs.).
check behind the right side of the front axle and look for 2 vacuum lines to see if they are still connected. also check on driver side just infront of the transfer case and check the vacuum lines to see if they are still connected. usually the problem is the vacuum lines have become caught on something and disconnected themselves.
need to check the central axle disconnect (cad) to make sure the vacuum lines are still attached, and check the vacuum pump to make sure it is working when you select 4wd. cad located on passenger side of front axle tube, vacuum pump located on transmission crossmember