I have just reinstalled the A4LD in my 1993 Explorer XLT 4wd. I would like to have found some more detailed instructions for reinstalling, but was unable to find them. The following tips would have helped me:
1. It is possible to remove and replace the A4LD from the 4.0 L without removing the crossover pipe. You have to lift the transmission up in the rear a little more to get its lower flanges over the pipe - then slide it out/in to remove/install. This extra effort saves a lot of time trying to get the crossover pipe off along with broken bolts, etc. It is also counter-intuitive to lift it up in the rear more, but that works as long as the engine is resting on the crossover pipe against the forward crossmember.
2. Before moving the transmission into position, clean the surfaces, use a tap to clear the bolt holes, and use some emery cloth to clean the receiver for the torque converter shaft and coat it with some grease.
3. When the transmission is inserted over the crossover pipe, level the transmission and slide it forward and align it. It might be necessary to wiggle it to get it to slip into place. Care should be taken so that the pipes, wires and mounting clips are carefully moved out of the way of the transmission to engine connection path. There are four medium length bolts with collars (neck of the bolt without threads) the same size as the bolt diameter, two shorter bolts with larger diameter collars and two longer bolts with collars the same size as the bolt. The longest two bolts go in the bottom holes, the two short bolts with larger collars go in the top. The four medium bolts go on the sides. The five fully threaded bolts nearly the same size as the medium bolts are for the transfer case.
4. The medium bolts through the locator guide posts are to be installed first on either side of the transmission. They go right through the locators. The threads will catch when within a 1/4" of the flange, but don't use the bolts to pull the transmission to the engine - if you do that you are asking for damage to the pump. It isn't right unless the transmission is fully in place against the engine and the torque converter bolts must match with the flex plate holes for that to happen. Note: The torque converter hub should be at least a half inch behind the surface of the transmission mounting bell. If it is not (the picture shows flush), the torque converter is not fully installed or has slipped out and must be corrected before things will go together.
5. Install the top bolts next. The left side bolt (driver's side) goes through the clip for the vent pipe and then through the left hole in the top bracket. Start the bolt in the hole and then position the spike on the vent pipe bracket into the top bracket. Holding the vent pipe in the approximate position, turn the bolt to near snug (you should be able to do this by hand using the extensions without the wrench). The right side bolt goes through the dipstick tube's bracket which must be in place, then through the right side hole of the top bracket - adjust the top bracket as necessary. Tighten the bolt to snug. Insert and bring all of the bolts to snug, then tighten the two side bolts, the top bolts and then the others to the torque values specified. Put the flex plate nuts on one at a time and tighten to the spec. I was able to put a 3/4 socket on the front crankshaft nut to turn the engine and watch as the stud was moved into position to install the nut. Turn only clockwise (looking at the front of the engine). You should be able to view the studs in the flex plate through the opening for the starter using a trouble light while you turn the engine. I crawled under the left (drivers) side to do this - my head toward the front of the vehicle.
6. After all of the connections and paraphernalia attachments have been made, put the front driveshaft in place (attach at the front) and then the transfer case should be attached. The transfer case's bottom bolt cannot be inserted when the transmission mount is installed, so use a jack at the back of the transmission to hold the transmission up while the transfer case is installed (or install the transfer case on the transmission before installing the transmission). Then install the driveshafts to the transfer case. Note: it is possible to insert the forward driveshaft after the transfer case is in place, just harder. I prefer to put the transfer case on after the transmission is in place because the transmission is lighter without it and I find that it is necessary to wiggle the transmission to get it to move forward into position. I am also not certain whether the transmission can be lifted enough to get over the crossover pipe if the transfer case is already installed.
7. Install the exhaust section and the transmission mount (the right side bolt holds the mount for the exhaust pipe as well). Then install the crossmember and the shield after all of the connections have been made. Reinstall the damper if used. Don't forget to refill the transfer case and the transmission. The transfer case uses about 2.5 qts and the transmission, etc, needs about 9 - 10 qts. Put at least 4 qts in to start. I was fooled by the thing showing full when it wasn't so exercise the transmission on the jack stands until it seems to be working right before drive test and then check the fluid levels frequently to assure that it is full.
8. I found that the mount for the transmission selector was difficult to put into place under the bracket for the transfer case vent pipe. I had installed the bolts with extensions for it on the top of the transmission, but only one goes in the top, the other goes on the driver's side, so I had to swap these two around once I figured out where the selector bracket had to go. It is wise to figure this out before installing the transmission. I did not find a clear picture of it, but was able to figure it out when I had the transmission in place and the only way it could possibly fit was as the picture actually showed - unclearly. I had to fiddle with it for awhile before it finally popped into place - unfortunately I could not do that ahead of time.
It would have been nice to find this stuff written down somewhere.
