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Section 1460 (Automatic Transmission - (Hybrid)): Installation: Transaxle

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G04620722
 Heavy Duty Floor Crane
014-00071 or equivalent
G04620723
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04620724
 Powertrain Lift
014-00765
G04620725
 Universal Adapter Brackets 014-0001
Lifting Bracket Set, Engine
303-D095 (D94L-6001-A) or equivalent
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
WARNING: To prevent exposure to high voltage, do not for any reason open the electronically controlled, continuously variable transmission (eCVT) cover. Failure to follow these instructions may result in personal injury.

    All vehicles 

    CAUTION: The damper contains a clutch which designed to slip briefly during vehicle operation. It is essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use grease on transmission input shaft or input shaft splines.
    Should the damper become contaminated it must be replaced.
    NOTE: Due to packaging requirements, the correct bolt must be used at the damper locations.
  1. Install the transaxle damper.
    • Tighten to 29 Nm (21 lb-ft).
      Fig 1: Locating Transaxle Damper
      G04620726Courtesy of FORD MOTOR CO.
    2. CAUTION: When positioning the engine to the transaxle, care must be taken to maintain alignment of the damper spline with the transaxle input shaft.
    NOTE: Transaxle removed from view for clarity.
  2. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 2: Locating Transaxle-To-Engine Bolts
      G04620727Courtesy of FORD MOTOR CO.
  3. Position the wiring harness in place and install the wiring harness fasteners on the transaxle stud bolts.
    Fig 3: Locating Wiring Harness Retainers And Wiring Harness To Transaxle Cover Stud Bolts
    G04620728Courtesy of FORD MOTOR CO.
  4. Connect the high voltage wiring harness electrical connector.
    Fig 4: Locating High Voltage Wiring Harness Electrical Connector
    G04620729Courtesy of FORD MOTOR CO.
  5. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
    6. CAUTION: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the lift table.
    Fig 5: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
    G03897890Courtesy of FORD MOTOR CO.
  6. Using the special tools, secure the engine to the lift table.
  7. Raise the engine and transaxle into the vehicle.
  8. Install the rear transaxle mount.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 6: Locating Rear Transaxle Mount
      G04620731Courtesy of FORD MOTOR CO.
  9. Install the rear transaxle mount bracket.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 7: Locating Rear Transaxle Mount Bracket
      G04620732Courtesy of FORD MOTOR CO.
  10. Install the RH transaxle mount bracket.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 8: Locating Bolts And RH Transaxle Mount Bracket
      G04620733Courtesy of FORD MOTOR CO.
  11. Install the RH transaxle mount bracket nut.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 9: Locating RH Transaxle Mount Bracket Nut
      G04620734Courtesy of FORD MOTOR CO.
  12. Install the engine mount bracket.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 10: Locating Engine Mount Bracket
      G04620735Courtesy of FORD MOTOR CO.
  13. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 11: Locating Engine Mount Bracket Bolt
      G04620736Courtesy of FORD MOTOR CO.
  14. Install the 2 transaxle-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 12: Locating Transaxle-To-Engine Bolts
      G04620737Courtesy of FORD MOTOR CO.
  15. Install the 2 transaxle-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 13: Locating Transaxle-To-Engine Bolts
      G04620738Courtesy of FORD MOTOR CO.
  16. Install the engine support crossmember, bolts and install a new nut.
    1. Tighten the bolts to 90 Nm (66 lb-ft).
    2. Tighten the nut to 175 Nm (129 lb-ft).
      Fig 14: Locating Engine Support Crossmember, Bolts
      G04620739Courtesy of FORD MOTOR CO.
  17. Position the roll restrictor bracket on the transaxle and install the rear roll restrictor bracket bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 15: Locating Rear Roll Restrictor Bracket Bolts
      G04620740Courtesy of FORD MOTOR CO.
  18. Install the front roll restrictor bolt.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 16: Locating Front Insulator Bolt
      G04620741Courtesy of FORD MOTOR CO.
  19. Install the A/C compressor.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 17: Locating A/C Compressor
      G04620742Courtesy of FORD MOTOR CO.
  20. Connect the lower radiator hose to the radiator.
    Fig 18: Locating Lower Radiator Hose
    G03897882Courtesy of FORD MOTOR CO.
  21. Install the motor electronics coolant pump.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 19: Locating Motor Electronics Coolant Pump
      G04620744Courtesy of FORD MOTOR CO.
  22. Install the wiring harness fasteners, the ground cable and nut.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 20: Locating Harness Fasteners, Nut And Ground Cable
      G04620745Courtesy of FORD MOTOR CO.
  23. Connect the transaxle coolant hoses.
    Fig 21: Locating Transaxle Coolant Hoses
    G04620746Courtesy of FORD MOTOR CO.
  24. Connect the motor electronics coolant temperature sensor electrical connector and pin-type retainer.
    Fig 22: Locating Motor Electronics Coolant Temperature Sensor Electrical Connector And Pin-Type Retainer
    G04620747Courtesy of FORD MOTOR CO.
  25. Install the selector lever cable in the retainer.
    Fig 23: Locating Selector Lever Cable Retainer
    G04620748Courtesy of FORD MOTOR CO.
  26. Connect the transaxle control cable.
    • Install the transaxle control cable bracket and the 2 nuts finger tight.
    • Attach the transaxle control cable to the control lever.
    • Tighten to 22 Nm (16 lb-ft).
      Fig 24: Locating Transaxle Control Cable
      G04620749Courtesy of FORD MOTOR CO.
  27. Position the control lever between the 2 casting ribs on the transaxle case.
    Fig 25: Identifying Control Lever Between Casting Ribs On Transaxle Case
    G04620750Courtesy of FORD MOTOR CO.
  28. Place the selector lever in the D position.
  29. Tighten the transaxle control cable bracket nuts to 22 Nm (16 lb-ft).
  30. To verify the correct cable adjustment, observe the control lever on the transaxle while an assistant shifts the selector lever to each range position ending in the D position.
  31. Install the transaxle control splash shield.
    • Tighten to 15 Nm (11 lb-ft).
      Fig 26: Locating Transaxle Control Splash Shield
      G04620751Courtesy of FORD MOTOR CO.
  32. Connect the steering gear electrical connector and wiring harness retainer.
    Fig 27: Locating Steering Gear Electrical Connector And Wiring Harness Retainer
    G04620752Courtesy of FORD MOTOR CO.
  33. Install the motor auxiliary coolant pump and connect the electrical connector.
    • Tighten to 10 Nm (89 lb-in).
      Fig 28: Locating Bolts And Coolant Pump Electrical Connector
      G04620753Courtesy of FORD MOTOR CO.
    34. NOTE: Parts removed from view for clarity.
  34. If equipped, install the block heater wiring harness.
    • Route the harness through the radiator support.
    • Attach the 3 harness retainer clips.
      Fig 29: Locating Harness Retainer Clips
      G04620754Courtesy of FORD MOTOR CO.
  35. Position the DC-to-DC converter in place and install the 3 nuts.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 30: Locating DC-To-DC Converter
      G04620755Courtesy of FORD MOTOR CO.
  36. Connect the DC-to-DC converter electrical connector and pin-type retainer.
    Fig 31: Locating DC-To-DC Converter Electrical Connector And Pin-Type Retainer
    G04620756Courtesy of FORD MOTOR CO.
  37. Connect the 2 low voltage electrical connectors and the engine harness-to-body harness retainer.
    Fig 32: Locating Low Voltage Electrical Connectors And Engine Harness-To-Body Harness Retainer
    G04620757Courtesy of FORD MOTOR CO.
  38. Connect the transaxle harness electrical connector and install the bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 33: Locating Transaxle Harness Electrical Connector
      G04620758Courtesy of FORD MOTOR CO.
  39. Install the selector lever cable fasteners on the transaxle stud bolts.
    Fig 34: Locating Selector Lever Cable Fasteners On Transaxle Stud Bolts
    G04620759Courtesy of FORD MOTOR CO.
  40. Connect the engine control harness electrical connector and the pin-type retainer.
    Fig 35: Locating Engine Control Harness Electrical Connector And Pin-Type Retainer
    G04620760Courtesy of FORD MOTOR CO.
  41. Install the ground strap on the PCM stud and install the nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 36: Locating Ground Strap On PCM Stud
      G04620761Courtesy of FORD MOTOR CO.
  42. Connect the engine control harness.
    • Engage the powertrain control module (PCM) connector.
    • Install the harness retaining nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 37: Identifying Engine Control Harness
      G04620762Courtesy of FORD MOTOR CO.
  43. Connect the upper radiator and coolant vent hoses.
    Fig 38: Locating Upper Radiator And Coolant Vent Hoses
    G04620763Courtesy of FORD MOTOR CO.
  44. Attach the heater hose retaining clip to the transaxle mount stud.
    Fig 39: Locating Heater Hose Retaining Clip To Transaxle Mount Stud
    G04620764Courtesy of FORD MOTOR CO.
  45. Connect the heater hoses to the heater core.
    Fig 40: Locating Heater Hoses
    G03897868Courtesy of FORD MOTOR CO.

    46. 4WD vehicles 

  46. Position the transfer case in place and install the 4 bolts.
    • Tighten to 45 Nm (33 lb-ft).
      Fig 41: Locating Transfer Case-To-Transaxle Bolts And Transfer Case
      G04620766Courtesy of FORD MOTOR CO.
  47. Connect the transfer case vent hose.
    Fig 42: Locating Transfer Case Vent Hose
    G04620767Courtesy of FORD MOTOR CO.
  48. Position the transfer case-to-engine support bracket and install the bolts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 43: Locating Transfer Case-To-Engine Support Bracket
      G04620768Courtesy of FORD MOTOR CO.
  49. Install the transfer case heat shield and the bolts.
    • Tighten to 14 Nm (10 lb-ft).
      Fig 44: Locating Transfer Case Heat Shield And Bolts
      G04620769Courtesy of FORD MOTOR CO.
  50. Install the driveshaft. For additional information, refer to DRIVESHAFT .

    51. All vehicles 

  51. Install the lateral support crossmember and the 4 bolts.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 45: Identifying Lateral Support Crossmember And Bolts
      G03897847Courtesy of FORD MOTOR CO.
  52. Install the front drive intermediate halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  53. Install the LH front drive halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  54. Install the engine coolant degas bottle. For additional information, refer to ENGINE COOLING - HYBRID .
  55. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
  56. Install the intake manifold. For additional information, refer to ENGINE - HYBRID 2.3L .
  57. Install the engine air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - HYBRID .
  58. Enable the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY .
  59. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  60. Reset the passive anti-theft system (PATS). For additional information, refer to ANTI-THEFT - PATS or ANTI-THEFT - PATS - HYBRID .
  61. Check and fill the transmission fluid level. For additional information, refer to TRANSMISSION FLUID DRAIN AND REFILL  in this article.
  62. Fill and bleed the motor electronics cooling system. For additional information, refer to TRANSAXLE-TRANSMISSION COOLING - HYBRID .
  63. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING - HYBRID .
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