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Installation (4WD)

WARNING: This page is about a different car, the 2002 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. Apply a thin coating of Premium Long Life Grease (XG-1-C or K) or equivalent to the spline of the input shaft. Secure the transaxle on a transmission jack. Raise the transaxle to the correct height and position the transaxle to the engine. Install the lower transaxle flywheel housing bolts. Remove the transmission jack.
  2. Position the aft-to-front crossmember and install the bolts and the nuts. See Figure . Tighten the aft-to-front crossmember bolts and nuts to specification. See TORQUE SPECIFICATIONS  . Position the transverse crossmember and install the bolts. See Figure . Tighten the transverse crossmember bolts to specification.
    3. CAUTION: DO NOT reuse center bearing nuts. Install NEW nuts only or damage to the vehicle will occur. DO NOT reuse the CV joint bolts and washers. Install NEW bolts and washers only or damage to the vehicle may occur.
  3. Install the driveshaft with help of an assistant. Install the center bearing nuts. See Figure . Tighten center bearing nuts to specification. See TORQUE SPECIFICATIONS  . Install the 6 front driveshaft-to-PTO bolts and washers. See Figure . Tighten driveshaft-to-PTO bolts to specification.
    4. CAUTION: DO NOT reuse the bolts and straps for the pinion yoke. Install NEW bolts and straps.
  4. Line up the pinion and yoke to the rear of the driveshaft and install the rear driveshaft universal joint caps bolts and straps. See Figure . Install the ground strap and bolt by the catalytic converter. See Figure . Tighten rear driveshaft universal joint caps bolts and ground strap bolt to specification. See TORQUE SPECIFICATIONS  .
  5. Install front axle shafts. See FWD AXLE SHAFTS - ESCAPE article. Position the left side splash under-shield and install the screws. Install the left side splash shield screws and the pin-type retainer. Lower the vehicle.
  6. Install the top transaxle flywheel housing bolts and tighten to specification. See TORQUE SPECIFICATIONS  . Position the wiring harness bracket and install starter motor bolts. See Figure . Tighten starter bolts to specification.
  7. Install the front transaxle support insulator and bracket bolt. See Figure . Install the left side transaxle support insulator bracket and tighten nuts to specification. See Figure . See TORQUE SPECIFICATIONS  . Install the left side transaxle support insulator bolts and tighten to specification. See Figure .
  8. Install the left side transaxle support insulator-to-bracket bolt and tighten to specification. See TORQUE SPECIFICATIONS  . Install the rear transaxle support insulator bolt. See Figure . Remove the 3 bar engine support kit. Install the clutch slave cylinder. See CLUTCH SLAVE CYLINDER  .
  9. Attach the clutch slave cylinder line to the bracket and install clip. Connect the VSS harness connector. See Figure . Install the ground strap and bolt near the shift cables. See Figure . Tighten ground strap bolt to specification. See TORQUE SPECIFICATIONS  .
  10. Install the gearshift and selector cables to the gearshift and selector levers, fully seat the lock clip. See Figure . Install the shift and selector cables to the brackets by sliding the cables onto the brackets and locking them in place.
  11. Attach the wire harness to the rear wire harness bracket. Install the front wire harness bracket. See Figure . Position the front wire harness bracket and install nut. Tighten nut to specification. See TORQUE SPECIFICATIONS  . Connect the reverse light switch harness connector.
  12. Position the air cleaner housing. See Figure . Install the air cleaner housing bolt. Connect the MAF sensor harness connector. Position and install the air cleaner outlet tube. See Figure . Tighten the air cleaner outlet tube clamp.
  13. Connect the crankcase ventilation hose. Attach the emission management tube and hose. Attach the accelerator cable to the air cleaner outlet tube. Install the 4 battery tray bolts. See Figure .
  14. Tighten the battery tray bolts to specification. See TORQUE SPECIFICATIONS  . Connect the pin-type wire clips at the front and the side of the battery tray. Install battery and tighten cables. Fill the transaxle to proper level with appropriate fluid. See SERVICING - M/T article in MANUAL TRANSMISSIONS.
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