Transaxle - All Wheel Drive (AWD): Installation

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: MERCON®, MERCON®V, MERCON®SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any fluid other than what is recommended for this transmission will cause transmission damage.

CAUTION: If a new transaxle or a mechatronic main control valve body assembly is installed, the TCM will need to be reflashed to the latest level calibration available. If the TCM is not reflashed, the wrench light on the dash may illuminate and internal transaxle damage may occur.

NOTE: If the transaxle was overhauled or if installing a new transaxle and the transmission fluid cooler tubes have not been flushed, flush the fluid cooler tubes at this time. For additional information, refer to TRANSMISSION FLUID COOLER TUBES - BACKFLUSHING AND CLEANING .

If the transaxle was overhauled or if installing a new transaxle and a new transmission fluid cooler has not been installed, install a new fluid cooler at this time. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING .

If installing a new transaxle, install the fluid level indicator and tube and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 1: Installing Fluid Level Indicator And Tube And Bolt
  Courtesy of FORD MOTOR CO.
If installing a new transaxle, install the transaxle insulator using new retainers.

Fig 2: Installing Transaxle Insulator Using Retainers
Courtesy of FORD MOTOR CO.
If removed, clean the rear transaxle mount bolts using a wire brush and apply new Threadlocker to the threads.
If installing a new transaxle, install the rear transaxle support insulator.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 3: Installing Rear Transaxle Support Insulator
  Courtesy of FORD MOTOR CO.
Prior to installing the original or a new transaxle, apply multi-purpose grease to the torque converter pilot hub.

Fig 4: Identifying Torque Converter Pilot Hub
Courtesy of FORD MOTOR CO.
Position the transaxle to the back of the engine.
Install the 3 transaxle-to-engine retaining bolts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 5: Locating Transaxle-To-Engine Bolts
  Courtesy of FORD MOTOR CO.
Install 4 new transmission fluid cooler tube seals.

Fig 6: Locating O-Ring Seals
Courtesy of FORD MOTOR CO.

CAUTION: Make sure that when installing the fluid cooler tubes they are installed straight or damage to the tubes will occur.

Connect the transmission fluid cooler tubes to the transaxle.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 7: Identifying Transmission Fluid Cooler Tubes To Transaxle Bolt
  Courtesy of FORD MOTOR CO.
Position the transmission fluid cooler tubes in place and install the bolts.
- Tighten to 10 Nm (89 lb-in)
  
  Fig 8: Positioning Transmission Fluid Cooler Tubes
  Courtesy of FORD MOTOR CO.
Install 4 new torque converter retaining nuts.
- Tighten to 36 Nm (27 lb-ft).
  
  Fig 9: Identifying Torque Converter Nuts
  Courtesy of FORD MOTOR CO.
Install the lower rubber access plug and install the retaining pin.

Fig 10: Locating Rubber Access Plug
Courtesy of FORD MOTOR CO.
Position the catalytic converter is place and loosely install the bolt for the bracket.

Fig 11: Locating Bolt At Catalytic Converter Bracket
Courtesy of FORD MOTOR CO.
Connect the HO2S electrical connector.

Fig 12: Connecting HO2S Electrical Connector
Courtesy of FORD MOTOR CO.
Using a suitable powertrain lift, position the subframe in place and install the 4 bolts.
- Tighten to 90 Nm (66 lb-ft).
  
  Fig 13: Installing Bolts
  Courtesy of FORD MOTOR CO.
Install the 2 bolts for the LH rear subframe mount.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 14: Installing Bolts For LH Rear Subframe Mount
  Courtesy of FORD MOTOR CO.
Install the 2 bolts for the RH rear subframe mount.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 15: Installing Bolts For RH Rear Subframe Mount
  Courtesy of FORD MOTOR CO.
Install the 2 bolts for the rear transaxle mount.
- Tighten to 90 Nm (66 lb-ft).
  
  Fig 16: Identifying Bolts For Rear Transaxle Mount
  Courtesy of FORD MOTOR CO.
Install the nut for the rear motor mount.
- Tighten to 70 Nm (52 lb-ft).
  
  Fig 17: Installing Nut For Rear Motor Mount
  Courtesy of FORD MOTOR CO.
Install the 2 bolts for the lower stabilizer mount.
- Tighten to 70 Nm (52 lb-ft).
  
  Fig 18: Installing Bolts For Lower Stabilizer Mount
  Courtesy of FORD MOTOR CO.
Install the nut for the front motor mount.
- Tighten to 70 Nm (52 lb-ft).
  
  Fig 19: Installing Nut For Front Motor Mount
  Courtesy of FORD MOTOR CO.
Position the splash shield in place and install the 3 push pins.

Fig 20: Installing Push Pins
Courtesy of FORD MOTOR CO.
Connect the HO2S electrical connector to the subframe.

Fig 21: Connecting HO2S Electrical Connector To Subframe
Courtesy of FORD MOTOR CO.
Position the power steering rack in place. Install the bolts and nuts.
- Tighten to 133 Nm (98 lb-ft).
  
  Fig 22: Installing Bolts And Nuts
  Courtesy of FORD MOTOR CO.
Position the power steering line in place and install the 4 bolts.
- Tighten to 7 Nm (62 lb-in).
  
  Fig 23: Installing Bolts
  Courtesy of FORD MOTOR CO.
Connect the wire harness to the LH front subframe.

Fig 24: Connecting Wire Harness To LH Front Subframe
Courtesy of FORD MOTOR CO.
Position the lower radiator hose in place and connect the retainers.

Fig 25: Positioning Lower Radiator Hose
Courtesy of FORD MOTOR CO.
Install the LH and RH stabilizer bar link into the struts and install new nuts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 26: Identifying Stabilizer Bar Link Nuts
  Courtesy of FORD MOTOR CO.
Remove the special tool from the lifting hook near the EGR valve.

Fig 27: Identifying Special Tools In Lifting Hook Near EGR Valve
Courtesy of FORD MOTOR CO.
Remove the special tools from the RH (rear) cylinder head.

Fig 28: Installing Special Tools To RH (Rear) Cylinder Head
Courtesy of FORD MOTOR CO.
Remove the special tools from the LH (front) cylinder head.

Fig 29: Installing Special Tools To LH (Front) Cylinder Head
Courtesy of FORD MOTOR CO.
Remove the special tools.

Fig 30: Identifying Special Tools To Support Engine Assembly
Courtesy of FORD MOTOR CO.
Install new bolts for the catalytic converter.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 31: Locating Bolts For Catalytic Converter
  Courtesy of FORD MOTOR CO.
Remove the upper half of the lifting hook.

Fig 32: Identifying Upper Half Of Lifting Hook
Courtesy of FORD MOTOR CO.
Remove the lower half of the lifting hook.

Fig 33: Identifying Lower Half Of Lifting Hook
Courtesy of FORD MOTOR CO.
Install the transaxle-to-engine bolt.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 34: Installing Transaxle-To-Engine Bolt
  Courtesy of FORD MOTOR CO.
Connect the knock sensor wire harness to the transaxle.

Fig 35: Connecting Knock Sensor Wire Harness To Transaxle
Courtesy of FORD MOTOR CO.
Install the knock sensor.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 36: Locating Knock Sensor
  Courtesy of FORD MOTOR CO.
Install the heat shield over the knock sensor.

Fig 37: Identifying Heat Shield Over Knock Sensor
Courtesy of FORD MOTOR CO.
If equipped, connect the engine block heater.

Fig 38: Locating Engine Block Heater
Courtesy of FORD MOTOR CO.
Position the power steering hose in place and install the bolt.
- Tighten to 7 Nm (62 lb-in).
  
  Fig 39: Installing Bolt
  Courtesy of FORD MOTOR CO.
Tighten the catalytic converter bolt to the bracket.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 40: Locating Bolt At Catalytic Converter Bracket
  Courtesy of FORD MOTOR CO.
Wipe off any residual grease or contaminants from the PTU splines.
- Apply a thin, uniform coating of constant velocity joint grease to all of the PTU spline surfaces before assembly.
Position the power transfer unit (PTU) and the rear driveshaft in place and install the 4 bolts.
- Tighten to 90 Nm (66 lb-ft).
  
  Fig 41: Identifying PTU Bolts
  Courtesy of FORD MOTOR CO.
Install the upper PTU bracket and the bolts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 42: Identifying Upper PTU Bracket Bolts And Bracket
  Courtesy of FORD MOTOR CO.
Install the LH and RH half shafts. For additional information, refer to FRONT DRIVE HALFSHAFTS .
Install the driveshaft cross brace.
- Tighten to 30 Nm (22 lb-ft).
  
  Fig 43: Identifying Driveshaft Cross Brace Mounting Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Align the index-marks made during removal.

NOTE: Use a crisscross pattern to tighten the bolts.

Using new bolts, install the driveshaft flange.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 44: Identifying Driveshaft Flange Bolts
  Courtesy of FORD MOTOR CO.
Position the exhaust crossover pipe and install 2 new bolts for the catalytic converter and connect the rubber hanger.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 45: Identifying Nuts For Catalytic Converter Pipe
  Courtesy of FORD MOTOR CO.
Install 2 new nuts for the rear exhaust pipe.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 46: Identifying Nuts For Rear Exhaust Pipe
  Courtesy of FORD MOTOR CO.
Install 2 new nuts for the front exhaust pipe.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 47: Identifying Exhaust Pipe Nuts
  Courtesy of FORD MOTOR CO.
Install the 4 upper transaxle bolts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 48: Installing Upper Transaxle Bolts
  Courtesy of FORD MOTOR CO.
Install the bolt for the power steering line.
- Tighten to 7 Nm (62 lb-in).
  
  Fig 49: Installing Bolt For Power Steering Line
  Courtesy of FORD MOTOR CO.
Connect the vapor tube to the canister purge valve.

Fig 50: Connecting Vapor Tube To Canister Purge Valve
Courtesy of FORD MOTOR CO.
Install the PCV hose.

Fig 51: Installing PCV Hose
Courtesy of FORD MOTOR CO.
Connect the vacuum hose to the throttle body.

Fig 52: Connecting Vacuum Hose To Throttle Body
Courtesy of FORD MOTOR CO.
Position the bracket for the power steering hose and install the bolt.
- Tighten to 7 Nm (62 lb-in).
  
  Fig 53: Positioning Bracket For Power Steering Hose
  Courtesy of FORD MOTOR CO.
Install the fluid cooler tube bracket to the transaxle.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 54: Identifying Fluid Cooler Tube Bracket/Bolt To Transaxle
  Courtesy of FORD MOTOR CO.
Connect the ground wire.
- Tighten to 12 Nm (9 lb-ft).
  
  Fig 55: Connecting Ground Wire
  Courtesy of FORD MOTOR CO.
Connect the wire harness to the transaxle.

Fig 56: Connecting Wire Harness To Transaxle
Courtesy of FORD MOTOR CO.

CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

Fig 57: Identifying Transaxle Bulkhead Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the transaxle bulk head electrical connector.
Install the starter motor.
- Tighten to 26 Nm (19 lb-ft).
  
  Fig 58: Installing Starter Motor
  Courtesy of FORD MOTOR CO.
Connect the 2 starter motor electrical connectors.
- Tighten the larger nut to 12 Nm (9 lb-ft).
- Tighten the smaller nut to 5 Nm (44 lb-in).
  
  Fig 59: Identifying Starter Motor Electrical Connectors
  Courtesy of FORD MOTOR CO.
Install the electrical cover for the starter motor electrical connectors.

Fig 60: Identifying Electrical Cover For Starter Motor Electrical Connectors
Courtesy of FORD MOTOR CO.
Clean the roll restrictor bolts using a wire brush and apply new Threadlocker to the threads.
Position the roll restrictor in place and install the bolts and connect the wire harness to the roll restrictor.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 61: Locating Wire Harness At Roll Restrictor
  Courtesy of FORD MOTOR CO.
Clean the 4 roll restrictor bracket bolts using a wire brush and apply new Threadlocker to the threads.
Install the roll restrictor bracket and the bolts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 62: Installing Roll Restrictor Bracket And Bolts
  Courtesy of FORD MOTOR CO.
Connect the lower wire harness to the transaxle.

Fig 63: Connecting Lower Wire Harness To Transaxle
Courtesy of FORD MOTOR CO.
If equipped, install the auxiliary coolant flow pump assembly.
1. Tighten to 7 Nm (62 lb-in).
2. Connect the electrical connector.
  
  Fig 64: Connecting Electrical Connector
  Courtesy of FORD MOTOR CO.
Connect the wire harness to the transaxle.

Fig 65: Locating Wire Harness At Transaxle
Courtesy of FORD MOTOR CO.
Install the shift cable bracket and bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 66: Installing Shift Cable Bracket And Bolts
  Courtesy of FORD MOTOR CO.
Connect the electrical connector to the shift cable bracket.

Fig 67: Locating Electrical Connector At Shift Cable Bracket
Courtesy of FORD MOTOR CO.
Connect the shift cable end.

Fig 68: Disconnecting Shift Cable End
Courtesy of FORD MOTOR CO.
Clean the 4 roll restrictor brace bolts using a wire brush and apply new Threadlocker to the threads.
Position the roll restrictor brace in place and install the 4 bolts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 69: Identifying Transaxle Roll Restrictor Bar Bolts
  Courtesy of FORD MOTOR CO.
Clean the upper roll restrictor bolt using a wire brush and apply new Threadlocker to the threads.
Install the upper roll restrictor bolt.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 70: Identifying Upper Roll Restrictor
  Courtesy of FORD MOTOR CO.
Install the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
Install the air cleaner and outlet tube. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
Install the battery tray and the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
If required, fill the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to TRANSMISSION FLUID LEVEL CHECK AND SETTING .
If a new transaxle or a mechatronic main control valve body assembly is installed, the TCM will need to be reflashed to the latest level calibration available. If the TCM is not reflashed, the wrench light on the dash may illuminate and internal transaxle damage may occur.